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Full text of "Yamaha Fazer FZS600 Service Manual"

YAMAHA 



FZS6Q0 * 





FZS600 

SERVICE MANUAL 

©1997 by Yamaha Motor Co., Ltd. 

First edition, December 1997 

All rights reserved. Any reproduction or 

unauthorized use without the written 

permission of Yamaha Motor Co., Ltd. 

is expressly prohibited. 



NOTICE 

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and 
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, 
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha 
scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. 
Repairs attempted by anyone without this knowledge are likely to render the scooter unfit for use. 

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and 
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers 
and will appear in future editions of this manual where applicable. 

NOTE: 

Designs and specifications ar subject to change without notice. 



IMPORTANT INFORMATION 

Particularly important information is distinguished in this manual by the following. 



A 



The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 
SAFETY IS INVOLVED! 



A WARNING 



Failure to follow WARNING instructions could result in severe injury or death to 
the motorcycle operator, a bystander or a person inspecting or repairing the 
motorcycle. 



CAUTION: 
NOTE: 



A CAUTION indicates special precautions that must be taken to avoid damage 
to the motorcycle. 

A NOTE provides key information to make procedures easier or clearer. 



HOW TO USE THIS MANUAL 

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive 
explanations of all installation, removal,disassembly, assembly, repair and inspection procedures are 
laid out with the individual steps in sequential order. 

©The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each 
page indicate the current chapter. Refer to "SYMBOLS" on the following page. 

©Each chapter is divided into sections. The current section title is shown at the top of each page, 
except in Chapter 3 ("Periodic Inspections and Adjustments"), where the sub-section title (-s) appear. 

(In Chapter3, "Periodic Inspections and Adjustments", the sub-section title appears at the top of each 
page, instead of the section title.) 

(3)Sub-section titles appear in smaller print than the section title. 

©To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each 
removal and disassembly section. 

©Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a 
disassembly step. 

©Symbols indicate parts to be lubricated or replaced (see "SYMBOLS"). 

©A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of 
parts, notes in jobs, etc. 

©Jobs requiring more information (such as special tools and technical data) are descrided 
sequentially. 






Removing the clutch 

Compression spring 
Pressure plate 
Short clutch push rod 

Ball 

Long clutch push rod 

Friction plate 

Clutch plate 

Fricition plate (large) 

Clutch spring plate 

Nut 



Remove the parts in the order listed. 



ENG \» 





ING THE CLUTCH 

1 . Straighten the lock washer tab. 

2. Loosen: 

• clutch boss nut® 

NOTE: 



3. Remove: 
• spacer CD 



Insert two M6-mm bolts © into the spacer 
and then remove the spacer by pulling on the 
bolls. J 



tion pi 

1. Check: 

• friction plate 

Damage/wear -► Replace the friction 
plates as a set. 

2. Measure: 

* friction plate thickness 

Out of specification -* Replace the friction 

plates as a set. 

NOTE: 

Measure the friction plate at four places. 



m 



Friction plate thickness 

2.94 ~ 3.06 mm 
<Llmit>: 2.8 mm 



CHECKING THE CLUTCH PLATES 

The following procedure applies to all of the 
clutch plates. 

1, Check: 

* clutch plate 

Damage -* Replace the clutch plates as a 

2. Measure: 

• clutch plate warpage 

(with a surface plate and thickness gauge 



/^y\ Clutch plate warpage limit 
Less than 0.1 mm 



m 



© 



GEN 
INFO 


<fr^ 



INSP 
ADJ 


<a 



cool y$ 



® 



CHAS 



<2J^ 



TRBL 
SHTG 


9 

• 



© 





SPEC 



© 



ENG 



% 



CARB 



9 



ELEC 



© 




© 



\ 



\ 




© 



a. 



i 




1 



i 



n 



New 



SYMBOLS 

The following symbols are not relevant to every 

vehicle. 

Symbols ® to (9) indicate the subject of each 

chapter. 

® General information 

(2) Specifications 

(3) Periodic inspection and adjustment 
® Engine 

(5) Cooling system 

(6) Carburetor(-s) 

(7) Chassis 

(8) Electrical system 

(9) Troubleshooting 

Symbols © to © indicate the following. 



© Serviceable with engine mounted 

© Filling fluid 

© Lubricant 

© Special tool 

@ Tightening torque 

© Wear limit, clearance 

© Engine speed 

@ Electrical data 

Symbols © to © in the exploded diagrams 

indicate the types of lubricants and lubrication 

points. 



© Apply engine oil 

© Apply gear oil 

© Apply molybdenum disulfide oil 

© Apply wheel bearing grease 

@ Apply lightweight lithium-soap base grease 

© Apply molybdenum disulfide grease 

Symbols @ to © in the exploded diagrams 

indicate the following: 

® Apply locking agent (LOCTITE®) 
© Use new one 



INDEX 


GENERAL INFORMATION 


#^ 


GEN El 

INFO| 


SPECIFICATIONS 


a- 


SPEcRJ 


PERIODIC INSPECTIONS AND 
ADJUSTMENTS 


toft 


CHK KfM 
ADJ CJ 


ENGINE 




ENG W*% 


COOLING SYSTEM 


tt 


COOL^J 


CARBURETORS 


9 


CARB^jJ 


CHASSIS 


$3® 


CHksWM 


ELECTRICAL SYSTEM 


a 


ELEcgj 


TROUBLESHOOTING 


9 

• 


TRBL W*% 
SHTG |fcj 



GEN 
INFO 


d*^ 



CHAPTER 1 
GENERAL INFORMATION 



MOTORCYCLE IDENTIFICATION 1-1 

VEHICLE IDENTIFICATION NUMBER 1-1 

MODEL CODE 1-1 

IMPORTANT INFORMATION 1-2 

PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2 

REPLACEMENT PARTS 1-2 

GASKETS, OIL SEALS AND O-RINGS 1-2 

LOCK WASHERS/PLATES AND COTTER PINS 1-3 

BEARINGS AND OIL SEALS 1-3 

CIRCLIPS 1-3 

CHECKING THE CONNECTIONS 1-4 

SPECIAL TOOLS 1-5 



MOTORCYCLE IDENTIFICATION 




GEN 
INFO 


d*^ 



GENERAL INFORMATION 
MOTORCYCLE IDENTIFICATION 

EB1 00010 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number® is stamped 
into the right side of the steering head. 



EB1 00020 

MODEL CODE 

The model code label ® is affixed to the frame. 
This information will be needed to order spare 
parts. 



1-1 



IMPORTANT INFORMATION 



GEN 
INFO 


^■^ 




300-008 



IMPORTANT INFORMATION 

PREPARATION FOR REMOVAL AND 
DISASSEMBLY 

1 . Before removal and disassembly, remove all 
dirt, mud, dust and foreign material. 

2. Use only the proper tools and cleaning 
equipment. 

Refer to the "SPECIAL TOOLS" section. 

3. When disassembling, always keep mated 
parts together. This includes gears, cylin- 
ders, pistons and other parts that have been 
"mated" through normal wear. 

Mated parts must always be reused or re- 
placed as an assembly. 

4. During disassembly, clean all of the parts 
and place them in trays in the order of disas- 
sembly. This will speed up assembly and al- 
low for the correct installation of all parts. 

5. Keep all parts away from any source of fire. 







I?" 


P^=^_ 


* - "^-»— . ■H 


^n< 


vx/r 


4 1 



EB1 02010 

REPLACEMENT PARTS 

1 . Use only genuine Yamaha parts for all re- 
placements. Use oil and grease recom- 
mended by Yamaha for all lubrication jobs. 
Other brands may be similar in-function and 
appearance, but inferior in quality. 





grease 



EB1 02020 

GASKETS, OIL SEALS AND O-RINGS 

1. When overhauling the engine, replace all 
gaskets, seals and O-rings. All gasket sur- 
faces, oil seal lips and O-rings must be 
cleaned. 

2. During reassembly, properly oil all mating 
parts and bearings and apply grease onto 
the oil seal lips. 



1-2 



IMPORTANT INFORMATION 



GEN 
INFO 


d*^ 




umuntnr m 



EB1 02030 

LOCK WASHERS/PLATES AND COTTER 
PINS 

1. After removal, replace all lock washers/ 
plates® and cotter pins. After the bolt or nut 
has been tightened to specification, bend 
the lock tabs along a flat of the bolt or nut. 








^^^ 




) — © 



EB1 02040 

BEARINGS AND OIL SEALS 

1. Install bearings and oil seals so that the 
manufacturer's marks or numbers are vis- 
ible. When installing oil seals, apply a light 
coat of lithium soap base grease onto the oil 
seal lips. Oil bearings liberally when instal- 
ling, if appropriate. 
© Oil seal 

CAUTION: 

Do not spin the bearing with compressed 
air because this will damage the bearing 
surfaces. 

© Bearing 



®o 


y 


P 


////M 




WM 

300-001 



EB1 02050 

CIRCLIPS 

1 . Before reassembly, check all circlips careful- 
ly and replace damaged or distorted circlips. 
Always replace piston pin clips after one 
use. When installing a circlips ®, make sure 
that the sharp-edged corner (2), is positioned 
opposite the thrust ® that the circlip re- 
ceives. 
® Shaft 



1-3 



CHECKING THE CONNECTIONS 



GEN 
INFO 


^■^ 






CHECKING THE CONNECTIONS 

Check the leads, couplers, and connectors for 
stains, rust, moisture, etc. 

1. Disconnect: 

• lead 

• coupler 

• connector 

2. Check: 

• lead 

• coupler 

• connector 

Moisture — ^Dry with an air blower. 
Rust/stains -► Connect and disconnect 
several times. 

3. Check: 

• all connections 

Loose connection -► Connect properly. 

NOTE: 

If the pin 2 on the terminal is flattened, bend 
in up. 

4. Connect: 

• lead 

• coupler 

• connector 

NOTE: 

Make sure that all connections are tight. 

5. Check: 

• continuity 

(with a pocket tester) 




Pocket tester 
90590-03112 



NOTE: 

• If there is no continuity, clean the termi- 
nals. 

• When checking the wire harness, perform 
steps 1 to 3. 

• As a quick remedy, use a contact revitaliz- 
er available at most part stores. 



1-4 



SPECIAL TOOLS 



GEN 
INFO 


d*^ 



SPECIAL TOOLS 

The following special tools are necessary for 
complete and accurate tune-up and assembly. 
Use only the appropriate special tools as this will 
help prevent damage caused by the use of 
inappropriate tools or improvised techniques. 
When placing an order, refer to the list provided 
below to avoid any mistakes. 



Tool No. 



Tool name/Usage 



Illustration 



90890-01268 



Ring nut wrench 



This tool is used to loosen and tighten the 
steering ringnut. 




90890-01304 



Piston pin puller 



This tool is used to remove the piston pin. 




90890-01460 
-01326 



Damper rod holder® 
T-handle© 



These tool ar used for holding the damper rod 
when removing or installing the damper rod. 




90890-01312 



Fuel level gauge 



This gauge is used to measure the fuel level 
in the float chamber. 



90890-01325 
-01352 



Radiator cap tester® 
Adaptor® 

These tools are used for checking the cooling 
system. 




90890-01362 
-01382 



Flywheel puller® 
Crank shaft protectory) 

These tools are used for removing the rotor 
and starter clutch. 




90890-01367 
-01381 



Fork seal driver weight 

Fork seal driver attachment (o41 mm) 

These tools are used when installing the 
forkseal. 





1-5 



SPECIAL TOOLS 



GEN 
INFO 


^■^ 



Tool No. 



Tool name/Usage 



Illustration 



90890-01399 



Special thickness gauge 



This tool is used to measure the valve 
clearance. 




90890-01401 



Spark plug wrench 



This tool is used for removing or installing 
the spark plug. 




90890-01403 



Ring nut wrench 



This tool is used to tighten the steering ring 
nut. 




90890-01469 



Oil filter wrench 



This tool is used for removing or installing 
the oil filter. 




90890-01701 



Sheave holder 



This tool is used for holding the magneto rotor. 




90890-03081 



Compression gauge 



This tool is used to measure the engine 
compression 




90890-03094 



Vacuum gauge 



This tool is used to measure the 
synchronizing the carburetors. 




90890-03112 



Pocket tester® 



These instruments are invaluable for 
checking the electrical system. 



® 



m 



90890-03133 



Engine tachometer 



This tool is needed for detecting engine rpm. 




90890-03153 
-03139 



Oil pressure gauge 
Oil pressure adaptor H 

These tools are used to measure the engine 
oil pressure. 




1-6 



SPECIAL TOOLS 



GEN 
INFO 


d*^ 



Tool No. 



Tool name/Usage 



Illustration 



90890-03141 



Timing light 



This tool is necessary for checking ignition 
timing. 




90890-04044 



Piston ring compressor 



This tool is used to compress piston rings 
when installing the cylinder. 




90890-03158 



Carburetor angle driver 



This tool is used to adjust the pilot screw. 




90890-04086 



Clutch holding tool 



This tool is used for holding the clutch boss. 




90890-04101 



Valve lapper 



This tool is used for removing and installing 
the valve lifter and for lapping the valve. 




90890-04111 



Valve guide remover (4.0 mm) 



This tool is used to remove the valve guides. 




90890-04112 



Valve guide installer (4.0 mm) 



This tool is needed to install the valve guides 
properly. 




90890-04113 



Valve guide reamer (4.0 mm) 



This tool is used to rebore the new valve 
guide. 




90890-04019 
-04114 



Valve spring compressor® 

Valve spring compressor attachment® 

These tools are used when removing or 
installing the valve and the valve spring. 




90890-06754 



Ignition checker 



This instrument is necessary for checking 
the ignition system components. 




1-7 



SPECIAL TOOLS 



GEN 
INFO 


^■^ 



Tool No. 


Tool name/Usage 


Illustration 


90890-85505 


Yamaha bond No. 121 5 

This sealant (bond) is used for crankcase 
mating surface, etc. 


*f 



1-8 



CHAPTER 2 
SPECIFICATIONS 

GENERAL SPECIFICATIONS 2-1 

MAINTENANCE SPECIFICATIONS 2-4 

ENGINE 2-4 

CHASSIS 2-10 

ELECTRICAL 2-14 

GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-17 

LUBRICATIONS AND LUBRICANT TYPES 2-18 

ENGINE 2-18 

CHASSIS 2-19 

COOLING SYSTEM DIAGRAMS 2-20 

LUBRICATION DIAGRAMS 2-22 

CABLE ROUTING 2-25 



SPEC 


a- 



SPEC 


a- 



GENERAL SPECIFICATIONS 



SPECIFICATIONS 
GENERAL SPECIFICATIONS 



SPEC 


a- 



Model 


FZS600 


Model code: 


5DM1 


Dimensions: 




Overall length 


2,080 mm 


Overall width 


710 mm 


Overall height 


1,170 mm 


Seat height 


790 mm 


Wheelbase 


1,415 mm 


Minimum ground clearance 


130 mm 


Minimum turning radius 


2,900 mm 


Basic weight: 




With oil and full fuel tank 


210 kg 


Engine: 




Engine type 


Liquid cooled 4-stroke, DOHC 


Cylinder arrangement 


Forward inclined parallel 4-cylinder 


Displacement 


599 cm 3 


Bore x stroke 


62.0 x 49.6 mm 


Compression ratio 


12 : 1 


Compression pressure (STD) 


1,550 kPa/400 r/min (15.5 kgf/cm 2 ) 


Starting system 


Electric starter 


Lubrication system: 


Wet sump 


Oil type or grade: 




Engine oil . 20 -10 o e To 20 30 40 ° c API STANDARD: 

i _ . . . 














w. 


bb or higher grade 
ACEA STANDARD: 
G4 or G5 




10W/30 






10W/40 






20W/40 






20W/50 






Periodic oil change 


2.5 L 


With oil filter replacement 


2.7 L 


Total amount 


3.5 L 


Radiator capacity 


1.95 L 


Total amount (including all routes) 




Air filter: 


Dry type element 


Fuel: 




Type 


Regular unleaded gasoline 


Fuel tank capacity 


18L 


Fuel reserve amount 


3.5 L 



2-1 



GENERAL SPECIFICATIONS 



SPEC 


a- 



Model 


FZS600 


Carburetor: 
Type/quantity 
Manufacturer 


BSR 33/4 
MIKUNI 


Spark plug: 
Type 

Manufacturer 
Spark plug gap 


CR9E, CR8E/U27ESR-NU24ESR-N 

NGK/DENSO 

0.7 - 0.8 mm 


Clutch type: 


Wet, multiple-disc 


Transmission: 
Primary reduction system 
Primary reduction ratio 
Secondary reduction system 
Secondary reduction ratio 
Transmission type 
Operation 
Gear ratio 1 st 

2nd 

3rd 

4th 

5th 

6th 


Spur gear 

82/48(1.708) 

Chain drive 

48/15(3.200) 

Constant mesh 6-speed 

Left foot operation 

37/13(2.846) 

37/19(1.947) 

34/22(1.545) 

28/21 (1.333) 

25/21 (1.190) 

29/27(1.074) 


Chassis: 
Frame type 
Caster angle 
Trail 


Double cradle 

24° 

88 mm 


Tire: 
Type 
Size front 

rear 
Manufacturer front 

rear 
Type front 

rear 


Tubeless 

110/70ZR17(54W) 

160/60ZR17(69W) 

BRIDGESTONE/DUNLOP 

BRIDGESTONE/DUNLOP 

BT-57F/D207F 

BT-57R/D207J 


Tire pressure: 
Maximum load-except motorcycle 
Loading condition A* 

front 

rear 
Loading condition B* 

front 

rear 
High-speed riding 

front 

rear 


187 kg 

~ 90 kg 

225 kPa (2.25 kg/cm 2 , 2.25 bar) 

250 kPa (2.5 kg/cm 2 , 2.5 bar) 

90 ~ 187 kg 

225 kPa (2.25 kg/cm 2 , 2.25 bar) 

280 kPa (2.8 kg/cm 2 , 2.8 bar) 

225 kPa (2.25 kg/cm 2 , 2.25 bar) 
280 kPa (2.8 kg/cm 2 , 2.8 bar) 



"Load is the total weight of cargo, rider, passenger, and accessories. 



2-2 



GENERAL SPECIFICATIONS 



SPEC 


a- 



Model 


FZS600 


Brake: 
Front brake type 

operation 
Rear brake type 

operation 


Dual disc brake 
Right hand operation 
Single disc brake 
Right foot operation 


Suspension: 
Front suspension 
Rear suspension 


Telescopic fork 

Swingarm (link suspension) 


Shock absorber: 
Front shock absorber 
Rear shock absorber 


Coil spring/Oil damper 
Coil spring/Gas-oil damper 


Wheel travel: 
Front wheel travel 
Rear wheel travel 


120 mm 
120 mm 


Electrical: 
Ignition system 
Generator system 
Battery type 
Battery capacity 


T.C.I, (digital) 
A.C. magneto 
GT12B-4 
12V 10 AH 


Headlight bulb type: 


Halogen bulb 


Bulb voltage, wattage x quantity: 
Headlight 
Brake/tail light 
Front turn signal light 
Rear turn signal light 
License light 
Meter light 
Indicator light 

Neutral indicator light 

High beam indicator light 

Oil level warning light 

Turn indicator light 

Fuel level warning light 

Engine temperature warning light 


12V60W/55W x 2 
12V21W/5W x 2 
12V 21 W x 2 
12V 21 W x 2 
12V 5 W x 2 
12V 2 W x 3 

12V 1.4 W x 1 
12V 1.4 W x 1 
12V 1.4 W x 1 
12V 1.4 W x 2 
12V 1.4 W x 1 
LED 



2-3 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



MAINTENANCE SPECIFICATIONS 

ENGINE 



Item 



Standard 



Limit 



Cylinder head: 
Warp limit 



0.05 mm 



Cylinder: 
Bore size 
Taper limit 
Out of round limit 



62.00 ~ 62.01 mm 



••• 
••• 



62.1 mm 
0.09 mm 
0.07 mm 



Camshaft: 
Drive method 
Cam cap inside dia. 
Camshaft out side dia. 
Camshaft to cap clearance 
Cam dimensions: 
Intake "A" 

"B" 

"C" 
Exhaust "A" 

"B" 

"C" 
Camshaft runout limit 




Chain drive (center) 
23.000 ~ 23.021 mm 
23.967 ~ 22.980 mm 
0.020 ~ 0.054 mm 

32.75 ~ 32.85 mm 
25.0 ~ 25.1 mm 
7.65 ~ 7.85 mm 
32.45 ~ 32.55 mm 
24.95 ~ 25.05 mm 
7.4 ~ 7.6 mm 



••• 
••• 



0.08 mm 

32.7 mm 
24.95 mm 
7.5 mm 
32.4 mm 
24.9 mm 
7.25 mm 
0.03 mm 



Cam chain: 
Cam chain type/No. of links 
Cam chain adjustment method 



92RH2010J/130 
Automatic 



••• 
••• 



Valve, valve seat, valve guide: 
Valve clearance (cold) IN 

EX 

Valve dimensions: 



0.11 
0.21 



0.20 mm 
0.30 mm 



'A"- 





"A" head dia. 
"B" face width 
"C" seat width 
"D" margin thickness 
Stem outside dia. 
Guide inside dia. 



Face Width 

IN 

EX 

IN 

EX 

IN 

EX 

IN 

EX 

IN 

EX 

IN 

EX 



Seat Width 



23.9 - 
20.9 - 
1.56 - 
1.56 - 
0.9 ~ 
0.9 ~ 
0.6 ~ 
0.6 ~ 
3.975 
3.960 
4.000 
4.000 



- 24.1 mm 

- 21.1 mm 

- 2.40 mm 

- 2.40 mm 
1.1 mm 
1.1 mm 
0.8 mm 
0.8 mm 

~ 3.990 mm 
~ 3.975 mm 
~ 4.012 mm 
~ 4.012 mm 



• •• 

• •• 



5c 



^.. D „ 



Margin Thickness 



1.6 mm 
1.6 mm 
0.5 mm 
0.5 mm 
3.95 mm 
3.935 mm 
4.042 mm 
4.042 mm 



2-4 





MAINTENANCE SPECIFICATIONS 


SPEC 


o- 




Item 


Standard 


Limit 


Stem-to-guide clearance IN 


0.010 ~ 0.037 mm 


0.08 mm 


EX 


0.025 ~ 0.052 mm 


0.1 mm 


Stem runout limit 


••• 


0.04 mm 


Valve seat width IN 


0.9 ~ 1.1 mm 


1.6 mm 


EX 


0.9 ~ 1.1 mm 


1.6 mm 


Valve spring: 






Free length IN/EX 


40.09 mm 


37.5 mm 


Set length (valve closed) IN/EX 


34.5 mm 


••• 


Compressed pressure IN/EX 


134 ~ 156 N (13.4 ~ 15.6 kg) 


••• 


Tilt limit IN/EX 


••• 


2.5°/1.8 mm 


Direction of winding IN/EX 


Clockwise 


••• 


Piston: 








Piston clearance t 
Piston size "D" 


-^V 


1 


0.025 ~ 0.050 mm 
61.960 ~ 61.975 mm 


0.07 mm 


Measuring point "H" r 




L H 


5 mm 




Piston off-set /L— D ' >,7 


i. 


0.5 mm 




Piston off-set direction 


In side 




Piston pin bore inside dia. 


17.002 ~ 17.013 mm 




Piston pin outside dia. 


16.991 ~ 17.000 mm 




Piston rings: 






Top ring: 






Type 


Barrel 


••• 


Dimensions (B x T) 


0.8 x 2.2 mm 


••• 


End gap (installed) 


0.15 ~ 0.30 mm 


0.6 mm 


Side clearance (installed) 


0.020 - 0.075 mm 


0.1 mm 


2nd ring: 






Type 


Taper 


••• 


Dimensions (B x T) 


0.8 x 2.3 mm 


••• 


End gap (installed) 


0.25 - 0.40 mm 


0.7 mm 


Side clearance (installed) 


0.020 - 0.055 mm 


0.1 mm 


Oil ring: 


1.5 x 2.3 mm 


••• 


End gap (installed) 


0.10 ~ 0.35 mm 


••• 


Connecting rod: 






Oil clearance 


0.043 ~ 0.066 mm 


0.08 mm 


Color code (corresponding size) 


1 . Blue 2. Black 3. Brown 4. Green 


••• 


Crankshaft: 
Crankshaft width "A" 
Assembly width "B" 


M 

jy uu u 


-A- 


48.4 mm 

296.8 - 298.0 mm 


••• 
••• 


Runout limit "P." 


B 




••• 


0.03 mm 
0.5 mm 


nuiiuui in 1 1 1 l \j r- -I 

Big end side clearance "D" 


0.160 ~ 0.262 mm 


Big end radial clearance "E" 


0.043 - 0.066 mm 


0.08 mm 


Small end free play "F" 


0.32 - 0.50 mm 


0.8 mm 


Journal oil clearance 


0.025 ~ 0.043 mm 


0.08 mm 


Color code (corresponding size) 


1 . Black 2. Brown 3. Green 4. Yellow 
5. Pink 


••• 



2-5 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Clutch: 






Friction plate thickness 


2.94 ~ 3.06 mm 


••• 


Quantity 


8 pes 


••• 


Wear limit 


••• 


2.8 mm 


Friction plate thickness 


2.94 ~ 3.06 mm 


••• 


Quantity 


1 pes 


••• 


Clutch plate thickness 


1.9 ~ 2.1 mm 


••• 


Quantity 


8 pes 


••• 


Warp limit 


••• 


0.1 mm 


Clutch spring free length 


34.9 mm 


••• 


Quantity 


6 pes 


••• 


Minimum length 


••• 


34.3 mm 


Clutch housing thrust clearance 


0.05 ~ 0.13 mm 


0.2 mm 


Clutch housing radial clearance 


0.005 ~ 0.041 mm 


••• 


Clutch release method 


Inner push, screw push 


••• 


Push rod bending limit 


••• 


0.3 mm 


Transmission: 






Main axle deflection limit 


••• 


0.02 mm 


Drive axle deflection limit 


••• 


0.02 mm 


Shifter: 






Shifter type 


Guide bar 


••• 


Guide bar bending limit 


••• 


0.05 mm 


Carburetor: 






I.D. mark 


5DM1 00 




Main jet (M.J) 


#115 




Main air jet (M.A.J) 


#80 




Jet needle (J.N) 


5D86 




Needle jet (N.J) 


P-0 




Pilot air jet (P.A.J. 1) 


#130 




Pilot outlet (P.O) 


0.9 




Pilot jet (P.J) 


#12.5 




Bypass 1 (B.P.1) 


0.9 




Bypass 2 (B.P.2) 


0.8 




Bypass 3 (B.P.3) 


0.8 




Pilot screw (P.S) 


2 




Valve seat size (V.S) 


1.0 




Starter jet (G.S.1) 


0.6 




Starter jet (G.S.2) 


0.8 




Throttle valve size (TH.V) 


#110 




Fuel level (F.L) (with 


4.5 mm 




special tool) 






Engine idle speed 


1,150 ~ 1,250r/min 




Intake vacuum 


30.7 ~ 33.3 kPa (230 ~ 250 mmHg) 





2-6 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Lubrication system: 






Oil filter type 


Paper type 


••• 


Oil pump type 


Trochoid type 


••• 


Tip clearance "A" or "B" 


0.03 ~ 0.09 mm 


0.15 mm 


Side clearance 


0.03 - 0.08 mm 


0.15 mm 


Bypass valve setting pressure 


80-120 kPa (0.8 ~ 1.2 kg/cm 2 ) 


••• 


Relief valve operating pressure 


450 ~ 550 kPa (4.5 ~ 5.5 kg/cm 2 ) 


••• 


Pressure check location 


Main gallery 


••• 


Cooling system: 






Radiator core size: 






Width 


320 mm 


••• 


Height 


161.4 mm 


••• 


Thickness 


27 mm 


••• 


Radiator cap opening pressure 


95-125 kPa (0.95 ~ 1.25 kg/cm 2 ) 


••• 


Radiator capacity 


0.6 L 


••• 


Reservoir tank capacity 


0.61 L 


••• 


From low to full level 


0.22 L 


••• 


Water pump: 






Type 


Single suction centrifugal pump 


••• 


Reduction ratio 


82/48 x 48/49(1.673) 


••• 



Item 


Size 


Bearings and oil seals: 




Big end bearing 


Plane 30 x 15 


Crankshaft bearing 


Plane 30 x 16 


Crankshaft oil seal 


S3-29-40-7.5L HS 


Water pump bearing 


BWF26-44R 


Water pump oil seal 


SD-1 2-28-7-1 HS 


Main axle bearing (left) 


Ball 6204DLA8NUR 


Main axle bearing (right) 


83B285SH2C3 22 x 56 x 16 


Drive axle bearing (left) 


83424ASH2CS41 


Drive axle bearing (right) 


20NQ3315NE20 x 33 x 15 


Drive axle oil seal 


SD7-35-52-8 VS 


Shift shaft oil seal 


SD-1 2-22-5 HS 



2-7 



MAINTENANCE SPECIFICATIONS 



TIGHTENING TORQUES 

ENGINE 



SPEC 


o- 



Part to be tightened 


Part name 


Thread 
size 


Q'ty 


Tightening 
torque 


Remarks 


Nm 


m*kg 


Camshaft cap 


Bolt 


M6 


24 


10 


1.0 




Cylinder head 


Nut 


M9 


12 


35 


3.5 


—(0 


Spark plug 


- 


M10 


4 


13 


1.3 




Cylinder head cover 


Bolt 


M6 


8 


10 


1.0 




Cylinder head side cover 


Bolt 


M5 


8 


9 


0.9 




Connecting rod cap 


Nut 


M7 


8 


See NOTE 


-4@M 


Camshaft sprocket 


Bolt 


M7 


4 


24 


2.4 




Timing chain tensioner case 


Bolt 


M6 


2 


10 


1.0 




Timing chain guide (intake side) 


Bolt 


M6 


2 


10 


1.0 


-a 


Timing chain tensioner cap 


Bolt 


M11 


1 


20 


2.0 




Pipe 2 


Bolt 


M6 


2 


10 


1.0 




Pipe 3/Pipe 4 


Bolt 


M6 


2 


10 


1.0 




Thermostat cover 


Bolt 


M6 


3 


10 


1.0 




Conduction assembly 


Bolt 


M6 


1 


10 


1.0 




Radiator 


Bolt 


M6 


3 


7 


0.7 




Joint 


Bolt 


M6 


4 


10 


1.0 




Water pump 


Bolt 


M6 


2 


10 


1.0 




Water pump housing 


Bolt 


M6 


2 


10 


1.0 




Radiator cover 


Bolt 


M6 


4 


8 


0.8 




Pipe 5/Pipe 6 


Bolt 


M6 


4 


10 


1.0 




Roter housing 


Screw 


M6 


1 


7 


0.7 




Oil pump assembly 


Bolt 


M6 


3 


10 


1.0 


h{3 


Strainer housing 


Bolt 


M6 


2 


10 


1.0 


h{3 


Strainer cover 


Bolt 


M6 


14 


12 


1.2 




Oil cooler 


Union bolt 


M20 


1 


63 


6.3 


—CD 


Oil drain bolt 


Bolt 


M14 


1 


43 


4.3 




Delivery pipe 


Bolt 


M10 


2 


20 


2.0 




Delivery pipe holder 


Bolt 


M6 


1 


10 


1.0 




Oil filter element 


- 


M20 


1 


17 


1.7 




Carburetor joint 1 .2 


Bolt 


M6 


8 


10 


1.0 




Cap case to air filter case 


Screw 


M5 


4 


1 


0.1 




Air filter case 


Bolt 


M6 


3 


7 


0.7 




Air filter cover to air clearance 


Screw 


M6 


6 


2 


0.2 




Exhaust pipe 


Nut 


M6 


8 


10 


1.0 




Exhaust joint 


Bolt 


M8 


1 


20 


2.0 




Crankcase 


Bolt 


M8 


12 


24 


2.4 


— ii(mJ 


Crankcase 


Bolt 


M6 


21 


12 


1.2 


—(0 


Crankcase 


Bolt 


M8 


1 


24 


2.4 


—(0 


Breather plate 


Screw 


M6 


6 


7 


0.7 


-a 


Oil seal stopper plate 


Bolt 


M6 


2 


10 


1.0 


-a 


AO magneto cover 


Bolt 


M6 


5 


12 


1.2 




Drive sprocket cover 


Bolt 


M6 


5 


10 


1.0 




Drive sprocket cover 


Screw 


M5 


4 


4 


0.4 


h{3 



2-8 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



Part to be tightened 


Part name 


Thread 
size 


Q'ty 


Tight* 
tore 


jning 
ue 


Remarks 


Nm 


m«kg 


Starter cover 


Bolt 


M6 


7 


12 


1.2 




Oil gallery 


- 


M16 


2 


8 


0.8 


—CD 


Clutch cover 


Bolt 


M6 


10 


12 


1.2 




Clamp (A.C magneto cover) 


Screw 


M6 


1 


7 


0.7 




Starter clutch assembly 


Bolt 


M10 


1 


80 


8.0 




Starter clutch outer 


Bolt 


M8 


3 


30 


3.0 


h{3 


Pressure plate 


Screw 


M6 


6 


8 


0.8 




Clutch boss 


Bolt 


M18 


1 


70 


7.0 




Push lever 


Screw 


M5 


2 


5 


0.5 


-a 


Push rod adjuster 


Nut 


M8 


1 


16 


1.6 




Drive sprocket 


Nut 


M18 


1 


70 


7.0 




Shift drum retainer 


Bolt 


M6 


1 


10 


1.0 


-a 


Shift arm 


Bolt 


M6 


1 


10 


1.0 




Shift fork guide bar retainer 


Bolt 


M6 


2 


10 


1.0 


-a 


Shift pedal adjuster 


Nut 


M6 


2 


7 


0.7 




Stopper lever 


Bolt 


M6 


1 


10 


1.0 


-a 


Side plate 2 


Screw 


M5 


1 


4 


0.4 


h{3 


A.C magneto roter 


Bolt 


M12 


1 


130 


13.0 




Stator coil 


Bolt 


M6 


3 


10 


1.0 


-a 


Pickup coil 


Screw 


M5 


2 


5 


0.5 




Starter motor 


Bolt 


M6 


2 


10 


1.0 




Neutral switch 


Screw 


M6 


2 


4 


0.4 




Oil level sensor 


Bolt 


M6 


2 


7 


0.7 




Thermo switch (fan motor) 


- 


M16 


1 


23 


2.3 




Thermo switch (warning light) 


- 


PT1/8 


1 


8 


0.8 




NOTF- 


After tightening to 15 Nm (1.5 m«kg), tighten another 90°. 



Crankcase tightening sequence 
Lower crankcase 









^dtp^@ra@^^(^ 




m 



Upper crankcase 




@ © 



2-9 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



CHASSIS 



Item 


Standard 


Limit 


Steering system: 
Steering bearing type 


Angular bearing 


••• 


Front suspension: 
Front fork travel 
Fork spring free length 
Fitting length 
Collar length 
Spring Rate (K1) 

(K2) 
Stroke (K1) 

(K2) 
Optional spring 
Oil capacity 
Oil level 
Oil grade 


120 mm 
323 mm 
315.9 mm 
200 mm 

7.5 N/mm (0.75 kg/mm) 
14 N/mm (1.4 kg/mm) 
- 70 mm 
70-120 mm 
No 
475 cm 3 

121 mm 

Fork oil 10W or equivalent 


••• 

319 mm 

••• 
••• 
••• 
••• 
••• 
••• 
••• 
••• 
••• 
••• 


Rear suspension: 
Shock absorber travel 
Spring free length 
Fitting length 
Spring Rate (K1) 
Stroke (K1) 
Optional spring 
Enclosed gas/air pressure (STD) 


50 mm 

177 mm 

168 mm 

147 N/mm (14.7 kg/mm) 

~ 50 mm 

No 

1200 kPa (12 kg/cm 2 ) 


••• 
••• 
••• 
••• 
••• 
••• 
••• 


Swingarm: 
Swingarm free play limit-end 
Swingarm free play limit-side 


••• 
••• 


1 mm 
1 mm 


Front wheel: 
Type 
Rim size 
Rim material 
Rim runout limit radial 
lateral 


Cast wheel 
17 x MT3.00 
Aluminum 

••• 
••• 


••• 
••• 
••• 

1 mm 
0.5 mm 


Rear wheel: 
Type 
Rim size 
Rim material 
Rim runout limit radial 
lateral 


Cast wheel 
17 x MT5.00 
Aluminum 

••• 
••• 


••• 
••• 
••• 

1 mm 
0.5 mm 


Drive chain: 
Type/manufacturer 
No. of links 
Chain free play 


50VA7/DAIDO 

110 

30 - 40 mm 


••• 
••• 
••• 



2-10 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Front disc brake: 
Type 

Disc outside dia. x thickness 
Disc deflection limit 
Pad thickness Inner 
Pad thickness Outer 
Master cylinder inside dia. 
Caliper cylinder inside dia. 

Brake fluid type 


Dual 

298 x 4 mm 

••• 

5.5 mm 
5.5 mm 
14 mm 
30.2 mm 
27 mm 
DOT No.4 


••• 
••• 

0.2 mm 
0.5 mm 
0.5 mm 
••• 
••• 
••• 
••• 


Rear disc brake: 
Type 

Disc outside dia. x thickness 
Disc deflection limit 
Pad thickness inner 
Pad thickness outer 
Master cylinder inside dia. 
Caliper cylinder inside dia. 
Brake fluid type 


Single 

245 x 5 mm 

••• 

5.5 mm 
5.5 mm 
12.7 mm 
38.1 mm 
DOT No.4 


••• 
••• 

0.15 mm 
0.5 mm 
0.5 mm 
••• 
••• 
••• 


Brake lever and brake pedal: 
Brake pedal position (N) 
Clutch lever free play (lever end) 
Throttle grip free play 


36.6 mm 
10 ~ 15 mm 
3 — 5 mm 


••• 
••• 
••• 



Item 


Size 


Bearings and oil seals: 




Pivot shaft bearing 


TA2428Z/24 x 31 x 28 


Front wheel bearing (left) 


6203LLU/2A17 x 40 x 12 


Front wheel bearing (right) 


6203LLU/2A17 x 40 x 12 


Rear wheel bearing (left) 


6204 2RS20 x 47 x 14 


Rear wheel bearing (right) 


6204 2RS20 x 47 x 14 


Rear wheel oil seal (right) 


SD-28-47-7-1 


Clutch hub bearing 


62062RS30 x 62 x 16 


Clutch hub oil seal 


MHSA-40-62-8-B 



2-11 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



TIGHTENING TORQUES 

CHASSIS 



Part to be tightened 


Thread size 


Tightening 
torque 


Remarks 


Nm 


m«kg 




Upper bracket and inner tube 


M8 x 1.25 


30 


3.0 




Upper bracket and steering stem 


M22 x 1.0 


110 


11.0 




Handlebar under holder 


M10 x 1.25 


40 


4.0 




Handlebar upper holder 


M8 x 1.25 


23 


2.3 




Under bracket and inner tube 


M10 x 1.25 


30 


3.0 




Ring nut (steering stem) 


M25 x 1.0 


- 


- 


NOTE 


Master cylinder bracket 


M6 x 1.0 


10 


1.0 




Master cylinder cap 


M4 x 0.7 


2 


0.2 




Brake hose union bolt 


M10 x 1.25 


30 


3.0 




Grip end 


M10 x 1.0 


7 


0.7 




Cowling stay 


M8 x 1.25 


33 


3.3 




Cowling bracket 


M6 x 1.0 


7 


0.7 




Front fender 


M6 x 1.0 


7 


0.7 




Engine bracket (front) 


M8 x 1.25 


33 


3.3 




Engine mount (front) 


M10 x 1.25 


55 


5.5 




Engine mount (rear upper) 


M10 x 1.25 


55 


5.5 




Engine mount (rear under) 


M10 x 1.25 


55 


5.5 




Engine bracket (rear) 


M8 x 1.25 


33 


3.3 




Pivot shaft 


M16 x 1.5 


11.5 


11.5 




Rear shock absorber (upper) 


M10 x 1.25 


40 


4.0 




Rear shock absorber and relay arm 


M10 x 1.25 


40 


4.0 




Relay arm and rear shock absorber bracket 


M10 x 1.25 


48 


4.8 




Relay arm and connecting rod 


M12 x 1.25 


48 


4.8 




Connecting rod and rear arm 


M12 x 1.25 


48 


4.8 




Chain guide 


M6 x 1.0 


7 


0.7 




Chain case 


M6 x 1.0 


7 


0.7 




Fuel tank (front) 


M6 x 1.0 


10 


1.0 




Fuel tank (rear) 


M6 x 1.0 


10 


1.0 




Fuel tank bracket (rear) 


M6 x 1.0 


7 


0.7 




Cap 


M5 x 0.8 


6 


0.6 




Fuel cock 


M6 x 1.0 


7 


0.7 




Fuel sender 


M5 x 0.8 


4 


0.4 




Ignition coil 


M6 x 1.0 


7 


0.7 




Seat lock 


M6 x 1.0 


7 


0.7 




Roter 


M6 x 1.0 


7 


0.7 




Rear fender and frame 


M6 x 1.0 


7 


0.7 




Taillight bracket and rear fender 


M6 x 1.0 


7 


0.7 




Tail cover and Taillight bracket 


M5 x 0.8 


4 


0.4 




Tail cover and frame 


M6 x 1.0 


7 


0.7 




Rear turn signal light 


M6 x 1.0 


7 


0.7 




Taillight 


M6 x 1.0 


4 


0.4 





2-12 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



Part to be tightened 


Thread size 


Tightening 
torque 


Remarks 


Nm 


m»kg 


Side cover and frame 


M6 x 1.0 


4 


0.4 




Garb bar 


M8 x 1.25 


19 


1.9 




Front wheel axle 


M16 x 1.5 


67 


6.7 




Front wheel axle pinch bolt 


M8 x 1.0 


20 


2.0 




Front brake caliper 


M8 x 1.25 


40 


4.0 




Front brake disc 


M8 x 1.25 


23 


2.3 


-i(3 


Front brake caliper bleed screw 


M7 x 1.0 


6 


0.6 




Compression bar 


M8 x 1.25 


23 


2.3 




Rear wheel sprocket 


M10 x 1.25 


60 


6.0 




Drive chain puller nut 


M8 x 1.25 


16 


1.6 




Rear brake caliper and caliper bracket 


M10 x 1.25 


40 


4.0 




Rear wheel axle nut 


M18 x 1.5 


117 


11.7 




Rear brake hose union bolt 


M10 x 1.25 


30 


3.0 




Rear brake caliper bleed screw 


M7 x 1.0 


6 


0.6 




Rear brake disc 


M8 x 1.25 


23 


2.3 


-i(3 


Sidestand 


M8 x 1.25 


23 


2.3 




Bracket footrest and frame 


M8 x 1.25 


28 


2.8 




Rear master cylinder and bracket 


M8 x 1.25 


23 


2.3 




Footrest bracket and footrest 


M10 x 1.25 


55 


5.5 




Footrest bracket (rear) and frame 


M8 x 1.25 


28 


2.8 




Center stand nut 


M10 x 1.25 


56 


5.6 




Footrest bracket and exhaust pipe 


M8 x 1.25 


20 


2.0 




Footrest bracket (rear) and muffler 


M10 x 1.25 


30 


3.0 




NOTF- 



1 . First, tighten the ring nut (lower) approximately 52 Nm (5.2 m*kg) by using the torque wrench, then 
loosen the right nut completely. 

2. Second, tighten the ring nut (lower) approximately 1 8 Nm (1 .8 m»kg) by using the torque wrench, 
then finger tighten the ring nut (center). Align the slots both ring nut and install the lock washer. 

3. Final, hold the ring nuts (lower and center) and tighten the ring nut (upper) 1 1 Nm (1 1 .0 m*kg) by 
using the torque wrench. 



2-13 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



ELECTRICAL 



Item 


Standard 


Limit 


Voltage 


12V 


••• 


Ignition system: 
Ignition timing (B.T.D.C.) 
Advanced timing (B.T.D.C.) 
Advance type 


10°/1,250r/min 
50°/4,500r/min 
TPS and electrical type 




T.C.I. : 
Pickup coil resistance 
T.C.I, unit model/manufacturer 


189 ~ 231 ft Y-L 
J4T085/MITSUBISHI 




Ignition coil: 
Model/manufacturer 
Primary winding resistance 
Secondary winding resistance 


J0313/DENSO 

1.87 ~ 2.53ftat20°C 

12 ~ 18kftat20°C 




Spark plug cap: 
Type 
Resistance 


Resin type 
10kft 




Charging system: 
Type 

Model/manufacturer 
Standard output 
Stator coil resistance 


A.C. magneto 
F4T359/MITSUBISHI 
12V18Aat5,000r/min 
0.36 ~ 0.44 ft at 20°C/W-W 




Voltage regulator: 
Type 

Model/manufacturer 
No load regulated voltage 


Semi conductor-short circuit type 
SH650-12/SHINDENGEN 
14.1 ~ 14.9 V 




Rectifier: 
Model/manufacture 
Capacity 
Withstand voltage 


SH650-12/SHINDENGEN 

18A 

200 V 




Battery: 
Specific gravity 


1,320 




Electric starter system: 
Type 


Constant mesh type 





2-14 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


Limit 


Starter motor: 
Model/manufacturer 
I.D. number 
Output 

Armature coil resistance 
Brush overall length 
Brush spring pressure 
Commutator dia. 
Mica undercut (depth) 


SM-13/MITSUBA 

SM-13 

0.7 kW 

0.0015 ~ 0.0025 ft at 20°C 

10 mm 

7.8 ~ 10.2 N (780 ~ 1.020 gf) 

28 mm 

0.7 mm 


••• 
••• 
••• 
••• 

4 mm 

••• 

27 mm 

••• 


Starter relay: 
Model/manufacturer 
Amperage rating 
Coil winding resistance 


MS5F-631/JIDECO 

100 A 

4.18 ~ 4.62ftat20°C 


••• 
••• 
••• 


Horn: 
Type 
Quantity 

Model manufacturer 
Maximum amperage 
Performance 
Coil winding resistance 


Plane type 

1 pes 

YF-12/NIKKO 

3.0 A 

105 ~ 120db/2m 

1.15 ~ 1.25ftat20°C 


••• 
••• 
••• 
••• 
••• 
••• 


Flasher relay: 
Type 

Model/manufacturer 
Self cancelling device 
Hazard flasher device 
Flasher frequency 
Wattage 


Full transistor type 

FE246BH/DENSO 

No 

Yes 

75 — 95 cyl/min 

21 W x 2 + 1.4W 


••• 
••• 
••• 
••• 
••• 
••• 


Oil level gauge: 
Model/manufacture 


4JH/SOMIC 


••• 


Fuel gauge: 
Model/manufacture 
Sender unit resistance -full 

-empty 


4YR/NIPPONSEIKI 
4 ~ 10ft 
90 ~ 100 ft 


••• 
••• 
••• 


Electric fan: 
Model/manufacturer 


5DM/DENSO 


••• 


Thermostat switch: 
Model/manufacture 


3LN/NIPPON THERMOSTAT 


••• 


Circuit breaker: 
Type 


Fuse 


••• 



2-15 



MAINTENANCE SPECIFICATIONS 



SPEC 


o- 



Item 


Standard 


limit 


Amperage for individual circuit: 






Main 


30 A 




Headlight 


20 A 




Signal 


20 A 




Ignition 


20 A 




Fan 


10A 




Back up 


5A 




Reserve 


30 A 
20 A 
10A 
5A 





2-16 



GENERAL TIGHTENING TORQUE SPECIFICATIONS 



SPEC 


o- 



GENERAL TIGHTENING TORQUE SPECIFICATIONS 

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tight- 
ening torque specifications for special components or assemblies are provided for each chapter of this 
manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive 
stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque 
specifications require clean, dry threads. Components should be at room temperature. 




A: Width across flats 
B: Thread diameter 



A 
(Nut) 


B 
(Bolt) 


General tightening 
torques 


Nm 


m»kg 


10 mm 


6 mm 


6 


0.6 


12 mm 


8 mm 


15 


1.5 


14 mm 


10 mm 


30 


3.0 


17 mm 


12 mm 


55 


5.5 


19 mm 


14 mm 


85 


8.5 


22 mm 


16 mm 


130 


13.0 



2-17 



LUBRICATION POINT AND LUBRICATION TYPES 
LUBRICATION POINT AND LUBRICATION TYPES 

ENGINE 



SPEC 


a- 



Lubrication Point 


Symbol 


Oil seal lips 


^fltsV* 


Bearing 


—CO 


Crankshaft journal 


-co 


Connecting rod big end and small end 


—CO 


Piston, piston pin 


—CO 


Connecting rod bolt 


— <<g 


Camshaft journal, profile 


— <0 


Valve stem (IN, EX) 


— <<g 


Valve stem end (IN, EX) 


-co 


Cylinder head tightening nut mounting surface 


—CO 


Valve lifter 


-co 


Camshaft cap 


-co 


Water pump seal 


Coolant 


Water pump shaft 


-«§»i 


Radiator hose 


Silicon 


Oil pump 


-co 


Relief valve O-ring 


^fltsV* 


Oil cooler O-ring 


^fltsV* 


Oil filter 


-«8»t 


Oil level gauge 


-co 


Starter moter O-ring 


^fltsV* 


Starter idrer gear 


-co 


Main axle 5, 6th pinion 


— <0 


Drive axle 1 — 4th wheel gear 


— <<g 


Push lever 


^fltsV* 


Push rod 


^fltsV* 


Shift cam 


—CO 


Shift fork guide bar 


—CO 


Shift shaft 


—CO 


Starter idrer gear shaft 1 


— <0 


Neutral switch O-ring 


-co 


Push rod 


-mgm\ 


Push rod 1 O-ring 


-«8»t 


Shift pedal 


-mgm\ 


Shift shaft 


-«8»t 


Water pump O-ring 


-mgm\ 


Cylinder head cover gasket 


Yamaha bond No. 1215 


Shift cam plug 


-a 


Breather plate 


-a 


Crankcase 


Yamaha bond No. 1215 


Taper plug 


-o 


Bearing plate 


-o 



2-18 



LUBRICATION POINT AND LUBRICATION TYPES 



SPEC 


a- 



CHASSIS 



Lubrication Point 


Symbol 


Steering bearing and bearing race (upper and lower) 


-m^\ 


Pivot shaft 


-*S»| 


Rear arm bearing 


-^M»| 


Rear arm oil seal 


-^M»| 


Rear arm cover oil seal lips 


-«e»t 


Relay arm bearing 


^®M* 


Relay arm oil seal 


-^M»| 


Rear shock absorber (upper/lower) 


-*S»| 


Front wheel oil seal 


-m@»\ 


Speed sensor oil seal 


-«§»i 


Rear wheel oil seal 


-«§»i 


Clutch damper oil seal 


-*§»i 


Clutch and rear wheel 


-*§»i 


Throttle cable inner surface 


-«§»i 


Starter cable inner surface and lever pivot 


-mgm\ 


Rear brake pedal shaft 


-*§»i 


Shift pedal shaft 


-*§»i 


Side stand sliding surface 


~^m\ 


Rear foot rest pivot bolt 


-«§»i 



2-19 



COOLING SYSTEM DIAGRAMS 



SPEC 


a- 



COOLING SYSTEM DIAGRAMS 



® Engine outlet hose 

(2) Engine outlet hose 

(3) Carburetor inlet hose 
® Carburetor outlet hose 

(5) Water pump 

(6) Coolant drain bolt 

(7) Water pump outlet hose 



(8) Radiator outlet hose 

(D Radiator 

(K) Radiator inlet hose 




2-20 



COOLING SYSTEM DIAGRAMS 



SPEC 


a- 



® Radiator 

(2) Water pump outlet hose 

(3) Oil cooler inlet hose 

(4) Oil cooler outlet hose 

(5) Carburetor outlet hose 




2-21 



LUBRICATION DIAGRAMS 



SPEC 


a- 



LUBRICATION DIAGRAMS 

® Oil nozzle (main nozzle) 

(2) Oil nozzle (drive axle) 

(3) Projection 
Oil filter 

(5) Relief valve 

(6) Oil strainer 

(7) Oil pump 






2-22 



® Main axle 

(2) Drive axle 

(3) Camshaft 

@ Oil delivery pipe 



LUBRICATION DIAGRAMS 



SPEC 


a- 




2-23 



® Camshaft 
(2) Crankshaft 



LUBRICATION DIAGRAMS 



SPEC 


a- 




2-24 



CABLE ROUTING 



SPEC 


a- 



CABLE ROUTING 

® Throttle cable 

(2) Clutch cable 

(3) Handlebar switch (right) 
® Starter cable 

(5) Main switch 

(6) Brake hose 

(7) Speed sensor lead 

(8) Headlight lead 



(D Handlebar switch (left) 
[A] Use a plastic clamp to fasten 
together the handlebar switch 
lead (left), clutch cable and 
starter cable. 
\B\ Pass the brake hose out side 
of the speed sensor lead, then 
use a plastic clamp to fasten 
them. 




2-25 



CABLE ROUTING 



SPEC 


a- 



® Main switch lead 

(2) Starter cable 

(D Handlebar switch lead (left) 

Clutch cable 

(5) Rectifier/ regulator 

(6) Horn lead 

(7) Box 

(8) Air guide plate 

(9) Starter cable 
© Flasher leray 



@ Battery 

© Starting circuit cut-off relay 

© Battery positive (+) lead 

@ Seat lock cable 

© AC magneto lead 

@ Starter motor lead 

© Air filter drain hose 

© Sidestand switch 

© Neutral switch 

® Oil level switch 



Speed sensor lead 

Horn 

Starter relay 

Fuse box 

To front brake switch 

To battery negative (-) lead 

To starter relay 

AC magneto coupler 

Pickup coupler 

Sidestand switch coupler 

Oil level/neutral switch coupler 




2-26 



CABLE ROUTING 



SPEC 


a- 



[A] Use a plastic clamp to fasten 
the handlebar switch lead (left), 
main switch lead, clutch cable 
and starter cable to the frame. 

\B\ Use a plastic band to fasten 
together wireharness, starter 
motor lead, AC magneto lead, 
sidestand switch lead and oil 
level/neutral switch lead, then 
hold the clamp to the frame 
bracket. 



Position the band end to out side of 

chassis. 

\C\ Use a plastic locking tie to 
fasten the starter motor lead, 
AC magneto lead, sidestand 
switch lead and oil level/neutral 
switch lead to the frame bracket. 
Cut off the excess end of the tie. 



\D\ Use a steel holder to fasten 
together the AC magneto lead, 
sidestand lead and oil 
level/neutral switch lead. 

[E] Use a plastic clamp to fasten 
the horn lead and air guide 
plate to the frame. 




2-27 



CABLE ROUTING 



SPEC 


a- 



© Battery negative (-) lead 

(2) Rear brake switch lead 

(3) Battery 

Reservoir tank hose 

(5) Air filter 

(6) Fuel tank breather hose 

(7) Fuel tank drain hose 
®T.P.S. lead 

(9) Handlebar switch lead (right) 



©Throttle cable 

© Brake hose 

© Headlight lead 

© Speed sensor lead 

@ Main switch lead 

© Reservoir tank 

© Cross tube 

© Reservoir tank over flow hose 

© Swingarm bracket 



[A] Use a plastic clamp to fasten 
together the throttle cables, 
headlight lead handlebar switch 
(right) and speed sensor lead. 

\B\ Use a plastic locking tie to 
fasten the handlebar switch 
(right) and brake hose to the 
right front fork inner tube. 




2-28 



CABLE ROUTING 



\C\ Pass the main switch lead under \E\ Pass the battery negative (-) 



the throttle cables, headlight 
lead, handlebar switch lead 
(right) and speed sensor lead, 
then insert it right side of the box. 
\D\ Pass the reservoir tank over 
flow hose, fuel tank breather 
hose and fuel tank drain hose 
through the cable holder. 



lead inside of the reservoir 
hose. 



SPEC 


a- 




2-29 



CABLE ROUTING 



SPEC 


a- 



® Throttle cable 

(2) Handlebar switch lead (right) 

(D Headlight lead 

® Speed sensor lead 

(5) Carburetor heater hose 

(6) Reservoir tank hose 

(7) Fuel pump 
® Fuel filter 
(9)T.P.SIead 

© Fuel sender, coupler 



© Battery negative (-) lead 

© Battery 

© Rear brake reservoir tank 

© Rear brake switch lead 

© Seat lock cable 

© Ignitor 

© Rear turn signal light lead (right) 

©Taillightlead 

© Rear turn signal light lead (left) 

<fib Starter motor lead 



» Starter relay 

» Starting circuit cut-off relay 

• Flasher relay 

• Fuel pump lead coupler 

• Ignition coil 

i Clutch cable 

• Ground lead 

i Starter cable 
i Fan motor lead 

• Rectifier/regulator lead 




2-30 



CABLE ROUTING 



SPEC 


a- 



® Starter cable 
© Clutch cable 
@) Handlebar switch lead (left) 
(§) Main switch lead 
©Totaillight 
® Rear fender 
©Clamp 

[A] Pass the wireharness under 
the starter relay. 



\B\ Pass the rectifier/ regulator 
lead, fan motor lead, handlebar 
switch lead (left), main switch 
lead, headlight lead, handlebar 
switch lead (right) and speed 
sensor lead through front side 
of the box, then connecte each 
coupler in the box. 

S3 Align the connector position of 
rear turn signal light leads (left 
and right), then bend the rear 



turn signal light lead and clamp 

it. 
\D\ Pass the reservoir hose left side 

of thermo stat housing. 
\E\ Do not fasten the high tension 

cord #4 with locking tie. 
[H Use a plastic band to fasten the 

high tension cord #3, #4. 
[G| Pass the carburetor inlet hose 

under the high tension cord #2, 

#4. 




2-31 



SPEC 


a- 



CHAPTER 3 
PERIODIC INSPECTIONS AND ADJUSTMENTS 

INTRODUCTION 3-1 

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1 

FRONT COWLING/SEAT/SIDE COVER/FUEL TANK 3-3 

ENGINE 3-5 

ADJUSTING THE VALVE CLEARANCE 3-5 

SYNCHRONIZING THE CARBURETORS 3-11 

ADJUSTING THE ENGINE IDLING SPEED 3-13 

ADJUSTING THE THROTTLE CABLE FREE PLAY 3-14 

CHECKING THE SPARK PLUGS 3-15 

CHECKING THE IGNITION TIMING 3-16 

MEASURING THE COMPRESSION PRESSURE 3-17 

CHECKING THE ENGINE OIL LEVEL 3-18 

CHANGING THE ENGINE OIL 3-19 

MEASURING THE ENGINE OIL PRESSURE 3-21 

ADJUSTING THE CLUTCH CABLE FREE PLAY 3-22 

CLEANING THE AIR FILTER ELEMENT 3-23 

CHECKING THE CARBURETOR JOINTS AND 

INTAKE MANIFOLDS 3-24 

CHECKING THE FUEL HOSES AND FUEL FILTER 3-24 

CHECKING THE CRANKCASE BREATHER HOSE 3-25 

CHECKING THE EXHAUST SYSTEM 3-25 

CHECKING THE COOLANT LEVEL 3-26 

CHECKING THE COOLING SYSTEM 3-26 

CHANGING THE COOLANT 3-27 

CHASSIS 3-30 

ADJUSTING THE FRONT BRAKE 3-30 

ADJUSTING THE REAR BRAKE 3-30 

CHECKING THE BRAKE FLUID LEVEL 3-31 

ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-32 

CHECKING THE BRAKE HOSES 3-33 

BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-33 

ADJUSTING THE SHIFT PEDAL 3-34 

ADJUSTING THE DRIVE CHAIN SLACK 3-35 

LUBRICATING THE DRIVE CHAIN 3-36 

CHECKING AND ADJUSTING THE STEERING HEAD 3-36 

CHECKING THE FRONT FORK 3-38 

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-38 

CHECKING THE TIRES 3-39 

CHECKING THE WHEELS 3-41 

CHECKING AND LUBRICATING THE CABLES 3-42 

LUBRICATING THE LEVERS AND PEDALS 3-42 

LUBRICATING THE SIDESTAND 3-42 

LUBRICATING THE CENTER STAND 3-42 

LUBRICATING THE REAR SUSPENSION 3-42 

ELECTRICAL SYSTEMS 3-43 

CHECKING AND CHARGING THE BATTERY 3-43 

CHECKING THE FUSES 3-48 

REPLACING THE HEADLIGHT BULBS 3-49 

ADJUSTING THE HEADLIGHT BEAMS 3-50 



CHK 
ADJ 


<& 



CHK 
ADJ 


«a 



CHK 
ADJ 


<& 



INTRODUCTION/ 
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 



PERIODIC INSPECTIONS AND ADJUSTMENTS 

INTRODUCTION 

This chapter includes all information necessary to perform recommended inspections and adjust- 
ments. If followed, these preventive maintenance procedures will ensure more reliable vehicle opera- 
tion, a longer service life and reduce the need for costly overhaul work. This information applies to ve- 
hicles already in service as well as to new vehicles that are being prepared for sale. All service 
technicians should be familiar with this entire chapter. 



PERIODIC MAINTENANCE/LUBRICATION INTERVALS 







ITEM 






INITIAL 
(1,000 km) 


EVERY 


NO. 


CHECKS AND MAINTENANCE JOBS 


6,000 km 
or 

6 months 
(whichever 
comes first) 


12,000 km 

or 
12 months 
(whichever 
comes first) 


1 


* 


Fuel line 




► Check fuel hoses and vacuum hose for cracks or 
damage. 

► Replace if necessary. 




V 


V 


2 


* 


Fuel filter 




► Check condition. 

► Replace if necessary. 






V 


3 




Spark plugs 




► Check condition. 

► Clean, regap or replace if necessary. 


V 


V 


V 


4 


* 


Valves 




► Check valve clearance. 

► Adjust if necessary. 


Every 42,000 km or 42 months 
(whichever comes first) 


5 




Air filter 




► Clean or replace if necessary. 




V 


V 


6 




Clutch 




► Check operation 

► Adjust or replace cable. 


V 


V 


V 


7 


* 


Front brake 




► Cehck operation, fluid level and vehicle for fluid 
leakage. (See NOTE.) 

► Correct accordingly. 

► Replace brake pads if necessary. 


V 


V 


V 


8 


* 


Rear brake 




► Check operation, fluid level and vehicle for fluid 
leakage. (See NOTE.) 

► Correct accordingly. 

► Replace brake pads if necessary. 


V 


V 


V 


9 


* 


Wheels 




► Check balance, runout and for damage. 

► Rebalance or replace if necessary. 




V 


V 


10 


* 


Tires 




► Check tread depth and for damage. 

► Replace if necessary. 

► Check air pressure. 

► Correct if necessary. 




V 


V 


11 


* 


Wheel bearings 




► Check bearing for looseness or damage. 

► Replace if necessary. 




V 


V 


12 


* 


Swingarm 




► Check swingarm pivoting point for play. 

► Correct if necessary. 

► Lubricate with molybdenum disulfide grease every 
24,000 km or 24 months (whichever comes first). 




V 


V 


13 




Dirve chain 




► Check chain slack. 

► Adjust if necessary. Make sure that the rear wheel is 
properly aligned. 

► Clean and lubricate. 


Every 1 ,000 km and after washing the 
motorcycle or riding in the rain 


14 


* 


Steering bearings 




► Check bearing play and steering for roughness. 

► Correct accordingly. 

► Lubricate with lithium soap base grease every 
24,000 km or 24 months (whichever comes first). 




V 


V 


15 


* 


Chassis fasteners 




► Make sure that all nuts, bolts and screws are properly 
tightened. 

► Tighten if necessary. 




V 


V 


16 


* 


Sidestand/ 
centerstand 




► Check operation. 

» Lubricate and repair if necessary. 




V 


V 



3-1 



PERIODIC MAINTENANCE/LUBRICATION INTERVALS 



CHK 
ADJ 


«a 







ITEM 


CHECKS AND MAINTENANCE JOBS 


INITIAL 
(1,000 km) 


EVERY 


NO. 


6,000 km 
or 

6 months 
(whichever 
comes first) 


12,000 km 

or 
12 months 
(whichever 
comes first) 


17 


* 


Sidestand switch 


• Check operation. 

• Replace if necessary. 


V 


V 


V 


18 


* 


Front fork 


• Check operation and for oil leakage. 

• Correct accordingly. 




V 


V 


19 


* 


Rear shock 

absorber 

assembly 


• Check operation and shock absorber for oil leakage. 

• Replace shock absorber assembly if necessary. 




V 


V 


20 


* 


Rear suspension 
relay arm and 
connecting 
arm pivoting 
points 


• Check operation. 

• Lubricate with molybdenum disulfide grease every 
24,000 km or 24 months (whichever comes first). 




V 


V 


21 


* 


Carburetors 


• Check engine idling speed, synchronization and 
starter operation. 

• Adjust if necessary. 


V 


V 


V 


22 




Engine oil 


• Check oil level and vehicle for oil leakage. 

• Correct if necessary. 

• Change. (Warm engine before draining.) 


V 


V 


V 


23 




Engine oil filter 
cartridge 


• Replace. 


V 




V 


24 


* 


Cooling system 


• Check coolant level and vehicle for coolant leakage. 

• Correct if necessary. 

• Change coolant every 24,000 km or 24 months 
(whichever comes first). 




V 


V 



*Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. 



NOTE: 



• The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 

• Brake fluid replacement 

1 . When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check 
the brake fluid level regularly and fill as required. 

2. Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. 

3. Replace the brake hose every four years or if cracked or damaged. 



3-2 



FRONT COWLING/ 
SEAT/SIDE COVER/FUEL TANK 



FRONT COWLING/SEAT/SIDE COVER/FUEL TANK 

FRONT COWLING 



CHK 
ADJ 


<a 




Order 



Job name/Part name 



Q'ty 



Remarks 



1 
2 
3 
4 
5 
6 
7 



Removing the front cowling 

View mirror (left/right) 

Inner panel (left/right) 

Cowling stay (left/right) 

Head light lead 

Front flasher light lead (left/right) 

Front cowling 

Head light assembly 



1/1 
1/1 
1/1 

2 
2/2 

1 

1 



Remove the parts in the order listed. 



NOTE: 



Disconnect the couplers. 



For installation, reverse the removal 
procedure. 



3-3 



FRONT COWLING/ 
SEAT/SIDE COVER/FUEL TANK 



SEAT, SIDE COVER AND FUEL TANK 



CHK 
ADJ 


<a 



W 19Nm(1.9m«kg) ] ^. j|@> 




>^ 4 Nm (0.4 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


1 


Removing the seat, side cover 
and fuel tank 

Seat 




Remove the parts in the order listed. 


2 
3 
4 
5 


Fuel tank 
Fuel sender lead 
Fuel tank breaser hose 
Fuel tank drain hose 




NOTE: 

Disconnect the couplers. 




6 


Fuel hose 






7 
8 


Side cover (left/right) 
Grab bar 


1/1 




9 


Tail cover 




For installation, reverse the removal 
procedure. 



3-4 



ADJUSTING THE VALVE CLEARANCE 



CHK 
ADJ 


<& 



ENGINE 

ADJUSTING THE VALVE CLEARANCE 

The following procedure applies to all of the 
valves. 

NOTE: 

• Valve clearance adjustment should be 
made on a cold engine, at room tempera- 
ture. 

• When the valve clearance is to be mea- 
sured or adjusted, the piston must be at top 
dead center (TDC) on the compression 
stroke. 

1. Remove: 

• front cowling 

• seat 

• fuel tank 

(Refer to "FRONT COWLING SEAT, SIDE 
COVER AND FUEL TANK" in chapter 3) 



2. Drain the coolant 
(Refer to "COOLANT REPLACEMENT" in 
chapter 3) 



3. Remove: 

• radiator 

(Refer to "RADIATOR" in chapter 5) 

4. Remove: 

• spark plug cap 

• spark plug 

• magneto cover 




5. Measure: 
• valve clearance 
Out of specification 



Adjust. 




Valve clearance (cold) 
Intake valve 

0.11 ~ 0.20 mm 
Exhaust valve 

0.21 ~ 0.30 mm 



3-5 



ADJUSTING THE VALVE CLEARANCE 




CHK 
ADJ 


«a 



m 



0° 180" 360" 540" 720" 



^ 



El 


#1 


#2 


#3 


#4 



■SI 










1111:11: 












llllll:: 






llllll 





11170401 



a. Turn the crankshaft counterclockwise. 

b. When piston #1 is at TDC on the com- 
pression stroke, align the TDC mark© on 
the generator rotor with the mark ® on 
the crankcase. 

NOTE: 

TDC on the compression stroke can be 
found when the camshaft lobes are turned 
away from each other. 

c. Measure the valve clearance with a thick- 
ness gauge®. 

NOTE: 

• If the valve clearance is incorrect, record 
the measured reading. 

• Measure the valve clearance in the follow- 
ing sequence. 



Valve clearance measuring sequence 
Cylinder #1 -+ #2 -+ #4 -+ #3 



El Front 

d. For each cylinder, starting with cylinder 
#1 at TDC, turn the crankshaft counter- 
clockwise as specified in the following 
table. 

\M Degrees that the crankshaft is turned 
counterclockwise. 

Cylinder 

03 Combustion cycle 



#2 Cylinder 


180° 


#4 Cylinder 


360° 


#3 Cylinder 


540° 



6. Remove: 
• carburetor 
Refer to "CARBURETION" in chapter 6. 



3-6 



ADJUSTING THE VALVE CLEARANCE 




CHK 
ADJ 


<& 



7. Remove: 

• timing chain tensioner bolt ® 

• timing chain tensioner assembly < 



® 


_V£?/ 

5K 


m 


'HI 


lfl2 


SL-c 




■^-J-—? 


J~fcf fe? — 


JcS 




_j<^LJ 






^iT^TI 


Ar\ \A— /^ 




voc '7> 


itl 


of 




(T) — q* 













8. Remove: 

• timing chain guide® 

• timing chain guide (upper) ® 

• camshaft cap ® 







|5M 




?7\ 


> \ 






j > 


^XD 







9. Remove: 
• camshaft ® 

NOTE: 



Refer to "DISASSEMBLING THE ENGINE 
- CAMSHAFT AND CYLINDER HEAD" in 
chapter 4. 

When removing the timing chain and cam- 
shafts, fasten a wire to the timing chain to 
retrieve it if it falls into the crankcase. 



10. Adjust: 

• valve clearance 



a. Remove the valve lifter ® and the valve 
pad®. 

NOTE: 

• Cover the timing chain opening with a rag 
to prevent the valve pad from falling into 
the crankcase. 

• Make a note of the position of each valve 
lifter ® and valve pad (2) so that they can 
be installed in the correct place. 

b. Select the proper valve pad from the fol- 
lowing table. 



Valve pad 
thickness range 


Available valve 
pads 


Nos. 

120 ~ 240 


120 ~ 
2.40 mm 


25 thickness 
in 0.05 mm 
increments 



3-7 



ADJUSTING THE VALVE CLEARANCE 



NOTE: 

• The thickness 



CHK 
ADJ 


«a 



D of each valve pad is 
marked in hundredths of millimeters on the 
side that touches the valve lifter. 
• Since valve pads of various sizes are origi- 
nally installed, the valve pad number must 
be rounded in order to reach the closest 
equivalent to the original. 

c. Round off the original valve pad number 
according to the following table. 



Last digit 


Rounded valve 


0or2 





5 


5 


8 


10 



EXAMPLE: 

Original valve pad number = 148 (thickness 

= 1.48 mm) 

Rounded value = 150 

d. Locate the rounded number of the origi- 
nal valve pad and the measured valve 
clearance in the valve pad selection 
table. 

The point where the column and row in- 
tersect is the new valve pad number. 

NOTE: 

The new valve pad number is only an 
approximation. The valve clearance must be 
measured again and the above steps should 
be repeated if the measurement is still incor- 
rect. 



3-8 



ADJUSTING THE VALVE CLEARANCE 



CHK 
ADJ 


<& 



VALVE PAD SELECTION TABLE 

INTAKE 





Measured 
clearance 

I 


INSTALLED PAD NUMBER 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




0.00 ~ 0.02 








120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 




0.03 ~ 0.07 






120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 




0.08 ~ 0.10 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 




0.11 ~ 0.20 


Specification 


exa 


0.21 ~ 0.22 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




-► 


0.23 ~ 0.27 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.28 ~ 0.32 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.33 ~ 0.37 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.38 ~ 0.42 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.43 ~ 0.47 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.48 ~ 0.52 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.53 ~ 0.57 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.58 ~ 0.62 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.63 ~ 0.67 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




EXAMPLE: 
VALVE CLEARANCE: 0.11 ~ 0.20 mm 
Installed is 150 

Measured clearance is 0.25 mm 
Replace 1 50 pad with 1 60 pad 




0.68 ~ 0.72 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.73 ~ 0.77 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.78 ~ 0.82 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.83 ~ 0.87 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.88 ~ 0.92 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.93 ~ 0.97 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.98 ~ 1.02 


205 


210 


215 


220 


225 


230 


235 


240 






1.03 ~ 1.07 


210 


215 


220 


225 


230 


235 


240 






1.08 ~ 1.12 


215 


220 


225 


230 


235 


240 






1.13 ~ 1.17 


220 


225 


230 


235 


240 






1.18 ~ 1.22 


225 


230 


235 


240 






1.23 ~ 1.27 


230 


235 


240 






1.28 ~ 1.32 


235 


240 






1.33 ~ 1.37 


240 



























EXHAUST 





Measured 
clearance 

I 


INSTALLED PAD NUMBER 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




0.00 ~ 0.02 












120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 




0.03 ~ 0.07 










120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 




0.08 ~ 0.10 








120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 




0.13 ~ 0.17 






120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 




0.18 ~ 0.20 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 




0.21 ~ 0.30 


Specification 


exa 


0.31 ~ 0.32 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




-► 


0.33 ~ 0.37 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.38 ~ 0.42 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.43 ~ 0.47 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.48 ~ 0.52 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.53 ~ 0.57 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.58 ~ 0.62 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 


EAR 
is 17 
d cle 
175 


ANCE:0.21 ~ 0.30 mm 

5 

arance is 0.35 mm 

pad with 185 pad 




0.63 ~ 0.67 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.68 ~ 0.72 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.73 ~ 0.77 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 


E) 


(AMPLE: 

/ALVE CL 

Installed 

Measure 

Replace 




0.78 ~ 0.82 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.83 ~ 0.87 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.88 ~ 0.92 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.93 ~ 0.97 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








0.98 ~ 1.02 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 








1.30 ~ 1.07 


200 


205 


210 


215 


220 


225 


230 


235 


240 






1.08 ~ 1.12 


205 


210 


215 


220 


225 


230 


235 


240 






1.13 ~ 1.17 


210 


215 


220 


225 


230 


235 


240 






1.18 ~ 1.22 


215 


220 


225 


230 


235 


240 






1.23 ~ 1.27 


220 


225 


230 


235 


240 






1.28 ~ 1.32 


225 


230 


235 


240 






1.33 ~ 1.37 


230 


235 


240 






1.38 ~ 1.42 


235 


240 






1.43 ~ 1.47 


240 

























3-9 



ADJUSTING THE VALVE CLEARANCE 




CHK 
ADJ 


«a 



Sill 


aw) w 1 


7^\ 


>\ 


J 7 ^ 



vfH£t4l|7U \ 
if i 4-U -U 4 — 



e. Install the new valve pad ® and the valve 
lifter®. 

NOTE: 

• Apply molybdenum disulfide grease to the 
valve pad. 

• Lubricate the valve lifter with molybdenum 
disulfide oil. 

• The valve lifter must turn smoothly when 
rotated by hand. 

• Install the valve lifter and the valve pad in 
the correct place. 

f. Install the exhaust and intake camshafts, 
timing chain and camshaft caps. 



Camshaft cap bolt 
10Nm(1.0irrkg) 



NOTE: 

• Refer to "CAMSHAFT" in chapter 4. 

• Lubricate the camshaft bearings, cam- 
shaft lobes and camshaft journals. 

• First, install the exhaust camshaft. 

• Align the camshaft marks ® with the cam- 
shaft cap marks. 

• Rotate the crankshaft counterclockwise 
several turns to seat the parts. 

CAUTION: _^^^ = ^^^^ 

The camshaft caps must be tightened 
evenly or damage to the cylinder head, 
camshaft caps and camshafts will result. 

g. Measure the valve clearance again. 

h. If the valve clearance is still out of specifi- 
cation, repeat all of the valve clearance 
adjustment steps until the specified clear- 
ance is obtained. 



11. Install: 

• all removed parts 

NOTE: 



For installation, reverse the removal proce- 
dure. Note the following points. 

12. Install: 

• timing chain guide (exhaust side) 

• timing chain guide (upper) 

• timing chain tensioner 

Refer to "CAMSHAFT" in CHAPTER 4. 

13. Install: 

• AC magneto cover 



Bolt (AC magneto cover): 
12Nm(1.2irrkg) 



3-10 



ADJUSTING THE VALVE CLEARANCE/ 
SYNCHRONIZING THE CARBURETORS 

14. Install: 

• cylinder head cover 

• spark plugs 



CHK 
ADJ 


<& 



V 



Bolt (cylinder head cover): 

10Nm(1.0nrkg) 
Spark plug: 

13Nm(1.3nvkg) 




EB303010 

SYNCHRONIZING THE CARBURETORS 

NOTE: 

Prior to synchronizing the carburetors, the 
valve clearance and the engine idling speed 
should be properly adjusted and the ignition 
timing should be checked. 

1 . Stand the motorcycle on a level surface. 

NOTE: 

Place the motorcycle on a suitable stand. 

2. Remove: 
• cap 





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S^l-c^il 





fa MY 

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^r|l© ©r 


— ^5^, 




p~® 



3. Install: 

• vacuum gauge ® 

• engine tachometer @ 

(to the spark plug lead of cyl. #1) 




Vacuum gauge 

90890-03094 
Engine tachometer 

90890-03113 



4. Start the engine and let it warm up for sever- 
al minutes. 

5. Check: 

• engine idling speed 
Out of specification -► Adjust. 
Refer to "ADJUSTING THE ENGINE ID- 
LING SPEED". 



C\ 



Engine idling speed 
1,150 ~ 1,250 r/min 



3-11 



SYNCHRONIZING THE CARBURETORS 



6. Adjust: 
• carburetor synchronization 



CHK 
ADJ 


«a 





G 


D , 






^^Jm 








■nanLl 










II =, S3JF§ 



a. Synchronize carburetor #1 to carburetor 
#2 by turning the synchronizing screw ® 
in either direction until both gauges read 
the same. 

NOTE: 

After each step, rev the engine two or three 
times, each time for less than a second, and 
check the synchronization again. 

b. Synchronize carburetor #4 to carburetor 
#3 by turning the synchronizing screw ® 
in either direction until both gauges read 
the same. 

c. Synchronize carburetor #2 to carburetor 
#3 by turning the synchronizing screw ® 
in either direction until both gauges read 
the same. 




Vacuum pressure at engine 

idling speed 
30.7 ~ 33.3 kPa 
(230 ~ 250 mm Hg) 



NOTE: 

The difference in vacuum pressure between 
two carburetors should not exceed 1 .33 kPa 
(10 mm Hg, 0.4 in Hg). 



7. Check: 
• engine idling speed 
Out of specification 



Adjust. 



8. Stop the engine and remove the measuring 
equipment. 

9. Adjust: 

• throttle cable free play 
Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY". 




Throttle cable free play (at 
the flange of the throttle grip) 
3-5 mm 



10. Install: 
• cap 



3-12 



ADJUSTING THE ENGINE IDLING SPEED 




CHK 
ADJ 


<& 



EB303020 

ADJUSTING THE ENGINE IDLING SPEED 

NOTE: 

Prior to adjusting the engine idling speed, 
the carburetor synchronization should be 
adjusted properly, the air filter should be 
clean, and the engine should have adequate 
compression. 

1 . Start the engine and let it warm up for sever- 
al minutes. 

2. Install: 

• engine tachometer 
(to the spark plug lead of cyl. #1) 



y- 



Engine tachometer 
90890-03113 



3. Check: 
• engine idling speed 
Out of specification ■ 



Adjust. 



€\ 



Engine idling speed 
1,150 ~ 1,250 r/min 



4. Adjust: 
• engine idling speed 



a. Turn the pilot screw ® in or out until it is 
lightly seated. 

b. Turn the pilot screw out by the specified 
number of turns. 




Carburetor angle driver: 
90890-03158 



Pilot screw: 2 turns out 



c. Turn the throttle stop screw® (a) or® un- 
til the specified idling speed is obtained. 



Direction (a) 



Idling speed is 
increased. 



Direction © 



Idling sped is 
decreased. 



5. Adjust: 
• throttle cable free play 
Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY". 




Throttle cable free play (at the 
flange of the throttle grip) 
3-5 mm 



3-13 



ADJUSTING THE THROTTLE CABLE FREE PLAY 



CHK 
ADJ 


«a 





EB303032 

ADJUSTING THE THROTTLE CABLE FREE 
PLAY 

NOTE: 

Prior to adjusting the throttle cable free play, 
the engine idling speed and carburetor syn- 
chronization should be adjusted properly. 

1. Check: 
• throttle cable free play (D 
Out of specification -+ Adjust. 




Throttle cable free play (at the 
flange of the throttle grip) 
3 — 5 mm 



2. Remove: 

• bracket 

• ignition coil 

• fuel pump 

3. Adjust: 

• throttle cable free play 



Carburetor side 

NOTE: 

When the motorcycle is accelerating, 
throttle cable #1 ® is pulled and throttle 
cable #2 (§) is pushed. 

a. Loosen the locknut © on throttle cable 
#2. 

b. Turn the adjuster ® © or © to take up 
any slack on throttle cable #2. 

c. Loosen the locknut © on throttle cable 
#1. 

d. Turn the adjuster © © or © until the spe- 
cified free play is obtained. 



Direction (a) 



Throttle cable free play 
is increased. 



Direction © 



Throttle cable free play 
is decreased. 



e. Tighten the locknuts. 
NOTE: 



If the specified throttle cable free play cannot 
be obtained on the carburetor side of the 
cable, use the adjusting nut on the handle- 
bar side. 

Handlebar side 

a. Loosen the locknut ®. 

b. Turn the adjusting nut © in direction (a) or 
© until the specified throttle cable free 
play is obtained. 



Direction (a) 



Throttle cable free play 
is increased. 



Direction © 



Throttle cable free play 
is decreased. 



c. Tighten the locknut. 



3-14 



ADJUSTING THE THROTTLE CABLE FREE PLAY/ 

CHECKING THE SPARK PLUGS 



A WARNING 



CHK 
ADJ 


<& 



After adjusting the throttle cable free 
play, turn the handlebar to the right and 
to the left to ensure that this does not 
cause the engine idling speed to change. 

4. Install: 

• fuel pump 

• ignition coil 

• bracket 

EB303040 

CHECKING THE SPARK PLUGS 

The following procedure applies to all of the 
spark plugs. 

1 . Disconnect: 

• spark plug cap 

2. Remove: 

• spark plug 

CAUTION: 




Before removing the spark plugs, blow 
away any dirt accumulated in the spark 
plug wells with compressed air to pre- 
vent it from falling into the cylinders. 

3. Check: 
• spark plug type 
Incorrect -► Change. 




Spark plug type (manufacturer) 
CR8E (NGK) 
U24ESR-N (DENSO) 



4. Check: 

• electrode ® 

Damage/wear -► Replace the spark plug. 

• insulator© 

Abnormal color -► Replace the spark plug. 
Normal color is a medium-to-light tan color. 

5. Clean: 

• spark plug 

(with a spark plug cleaner or wire brush) 

6. Measure: 

• spark plug gap ® 

(with a specification -► Regap. 




Spark plug gap 
0.7 - 0.8 mm 



7. Install: 
• spark plug 



X 



Spark plug 
13Nm(1.3m»kg) 



NOTE: 

Before installing the spark plug, clean the 
spark plug and gasket surface. 



3-15 



CHECKING THE SPARK PLUGS/ 
CHECKING THE IGNITION TIMING 



CHK 
ADJ 


«a 






fSC s^^&sSJ-m^ 


^^£5^: 




MWR 






mm 




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8. Connect: 
• spark plug cap 



EB303053 

CHECKING THE IGNITION TIMING 
NOTE: 



Prior to checking the ignition timing, check 
the wiring connections of the entire ignition 
system. Make sure that all connections are 
tight and free of corrosion. 

1. Remove: 

• timing plug® 

2. Install: 

• timing light® 

• engine tachometer (2) 

(to the spark plug lead of cyl. #1) 



y- 



Timing light 

90890-03141 
Engine tachometer 

90890-03113 



3. Check: 
• ignition timing 



a. Start the engine, warm it up for several 
minutes, and then let it run at the speci- 
fied engine idling speed. 



€\ 



Engine idling speed 
1,150 ~ 1,250 r/min 



b. Check that the stationary pointer ® is 
within the firing range ® on the generator 
rotor. 

Incorrect firing range — ► Check the igni- 
tion system. 

NOTE: 

The ignition timing is not adjustable. 

4. Remove: 

• engine tachometer 

• timing light 



5. Install: 
• timing plug 



3-16 



MEASURING THE COMPRESSION PRESSURE 



CHK 
ADJ 


<& 




EB303060 

MEASURING THE COMPRESSION 
PRESSURE 

The following procedure applies to all of the cyl- 
inders. 

NOTE: 

Insufficient compression pressure will result 
in a loss of performance. 

1 . Check: 

• valve clearance 

Out of specification -► Adjust. 

Refer to "ADJUSTING THE VALVE 

CLEARANCE". 

2. Start the engine, warm it up for several min- 
utes, and then turn it off. 

3. Disconnect: 

• spark plug cap 

4. Remove: 

• spark plug 

CAUTION: 



Before removing the spark plugs, use 
compressed air to blow away any dirt ac- 
cumulated in the spark plug wells to pre- 
vent it from falling into the cylinders. 

5. Install: 
• compression gauge ® 




Compression gauge 
90890-03081 



Measure: 

• compression pressure 

Above the maximum pressure — ► Inspect 
the cylinder head, valve surfaces, and pis- 
ton crown for carbon deposits. 
Below the minimum pressure — ► Squirt a 
few measure again. 

• Refer to the following table. 



Compression pressure 
(with oil applied into the cylinder) 


Reading 


Diagnosis 


Higher than 
without oil 


Piston wear or 
damage -+ Repair. 


Same as 
without oil 


Piston ring(-s), 
valves cylinder 
head gasket or 
piston possibly 
defective -► Repair. 



3-17 



MEASURING THE COMPRESSION PRESSURE/ 
CHECKING THE ENGINE OIL LEVEL 



CHK 
ADJ 


«a 




Compression pressure 
(at sea level) 
Standard 

1,500 kPa (15.0 kg/cm 2 ) 
Minimum 
1,200 kPa (12.0 kg/cm 2 ) 



a. Turn the main switch to "ON". 

b. With the throttle wide open, crank the en- 
gine until the reading on the compression 
gauge stabilizes. 



A WARNING 



To prevent sparking, ground all spark 
plug leads before cranking the engine. 

NOTE: 

The difference in compression pressure 
between cylinders should not exceed 100 
kPa (1 kg/cm 2 , 1 bar). 

7. Install: 
• spark plug 



Spark plug 
13Nm(1.3irrkg) 



8. Connect: 
• spark plug cap 




EB303070 

CHECKING THE ENGINE OIL LEVEL 

1 . Stand the motorcycle on a level surface. 

NOTE: 

• Place the motorcycle on a suitable stand. 

• Make sure that the motorcycle is upright. 

2. Let the engine idle for a few minutes. 

3. Check: 

• engine oil level 

The engine oil level should be between the 
minimum level marks (D and maximum 
level marks®. 

Below the minimum level mark — ► Add the 
recommended engine oil to the proper lev- 
el. 



3-18 



CHECKING THE ENGINE OIL LEVEL/ 
CHANGING THE ENGINE OIL 



CHK 
ADJ 


<& 



-30 -20 


-10 10 20 30 40 TEMP (°C) 


■ ■■■' i i 

1 
1 


SAE10W-30 


KZ 


j\ I 


i 
i 
i 
i 


| SAE10W-30 




SAE 10W-30 


Minium >i 






•ft 



Recommended engine oil 
Refer to the chart for the 
engine oil grade which is best 
suited for certain atmospheric 
temperatures. 
API standard -+ 

SE or higher grade 
ACEA standard -► G4 or G5 



CAUTION: 

• Engine oil also lubricates the clutch and 
the wrong oil types or additives could 
cause clutch slippage. Therefore, do not 
add any chemical additives or use 
engine oils with a grade of CD (a) or 
higher and do not use oils labeled 
"ENERGY CONSERVING II" © or higher. 

• Do not allow foreign materials to enter 
the carankcase. 

4. Start the engine, warm it up for several min- 
utes, and then turn it off. 

5. Check the engine oil level again. 

NOTE: 

Before checking the engine oil level, wait a 
few minutes until the oil has settled. 




EB303081 

CHANGING THE ENGINE OIL 

1 . Start the engien, warm it up for several min- 
utes, and then turn it off. 

2. Place a container under the engine oil drain 
bolt. 

3. Remove: 

• engine oil filler cap® 

• engine oil drain bolt (2) 
(along with the gasket) 

4. Drain: 

• engine oil 

(completely from the crankcase) 

5. If the oil filter cartridge is also to be replaced, 
perform the following procedure. 



3-19 



<a 



w\ 




I 


® ^\ 








3-20 



MEASURING THE ENGINE OIL PRESSURE 



CHK 
ADJ 


<& 




EB303090 

MEASURING THE ENGINE OIL PRESSURE 

1. Check: 

• engine oil level 

Below the minimum level mark — ► Add the 
recommended engine oil to the proper lev- 
el. 

2. Start the engine, warm it up for several min- 
utes, and then turn it off. 

CAUTION: 

When the engine is cold, the engine oil 
will have a higher viscosity, causing the 
engine oil pressure to increase. There- 
fore, be sure to measure the engine oil 
pressure after warming up the engine. 

3. Remove: 

• oil gallery bolt® 



A WARNING 



The engine, muffler and engine oil are 
extremely hot. 

4. Install: 

• oil pressure gauge ® 

• adapter (§) 



y- 



Oil pressure gauge 

90890-03153 
Adapter 

90890-03139 



5. Measure: 
• engine oil pressure 
(at the following conditions) 




Engine oil pressure 
450 kPa (4.5 kg/cm 2 ) 

Engine speed 
Approx. 10,000 r/min 

Engine oil temperature 
115°C 



Out of specification -► Adjust. 



Engine oil pressure 


Possible cause 


Below specification 


Faulty oil pump 
Clogged oil filter 
Leaking oil passage 
Broken or damaged 
oil seal 


Above specification 


Leaking oil passage 
Faulty oil filter 
Oil viscosity too 
high 



3-21 



MEASURING THE ENGINE OIL PRESSURE/ 
ADJUSTING THE CLUTCH CABLE FREE PLAY 



6. Install: 
• oil gallery bolt 



CHK 
ADJ 


<a 



8 Nm (0.8 rrvkg) 




EB303100 

ADJUSTING THE CLUTCH CABLE FREE 
PLAY 

1. Check: 
• clutch cable free play ® 
Out of specification -+ Adjust. 




Clutch cable free play (at the 
end of the clutch lever) 
10 ~ 15 mm 



2. Adjust: 
• clutch cable free play 



Handlebar side 

a. Loosen the locknut ®. 

b. Turn the adjusting bolt (2) in direction (a) or 
® until the specified clutch cable free 
play is obtained. 



Direction (a) 



Clutch cable free 
play is increased. 



Direction ® 



Clutch cable free 
play is decreased. 



c. Tighten the locknut. 
NOTE: 



If the specified clutch cable free play cannot 
be obtained on the handlebar side of the 
cable, use the adjusting nut on the engine 
side. 

Engine side 

a. Loosen the locknuts ®. 

b. Turn the adjusting bolt® in direction © or 
@ until the specified clutch cable free 
play is obtained. 



Direction @ 



Clutch cable free 
play is increased. 



Direction (§) 



Clutch cable free 
play is decreased. 



c. Tighten the locknuts. 



3-22 



CLEANING THE AIR FILTER ELEMENT 




CHK 
ADJ 


<& 






EB303130 

CLEANING THE AIR FILTER ELEMENT 

1. Remove: 

• Seat 

• Fuel tank 

• Cover ® 



2. Remove: 

• air filter case cover ® 

• air filter element® 



3. Clean: 
• air filter element 
Apply compressed air to the outer surface 
of the air filter element. 



4. Check: 

• air filter element 
Damage -► Replace. 

5. Install: 

• air filter element 

• air filter case cover 

CAUTION: 



Never operate the engine without the air 
filter element installed. Unfiltered air will 
cause rapid wear of engine parts and may 
damage the engine. Operating the engine 
without the air filter element will also af- 
fect the carburetor turning, leading to 
poor engine performance and possible 
overheating. 



3-23 



CLEANING THE AIR FILTER ELEMENT/ 

CHECKING THE CARBURETOR JOINTS AND IN TAKE MANIFOLDS/ 

CHECKING THE FUEL HOSES AND FUEL FILTER 



CHK 
ADJ 


«a 




NOTE: 

When installing the air filter element into the 
air filter case cover, be sure their sealing sur- 
faces are aligned to prevent any air leaks. 

6. Install: 

• cover 

• fuel tank 

• seat 

EB303171 

CHECKING THE CARBURETOR JOINTS 
AND INTAKE MANIFOLDS 

The following procedure applies to all of the car- 
buretor joints and intake manifolds. 

1. Remove: 

• seat 

• fuel tank 

2. Check: 

• carburetor joint® 

• intake manifold (D 
Cracks/damage -► Replace. 

Refer to "CARBURETOR" in chapter 6. 

3. Install: 

• fuel tank 

• seat 

EB303181 

CHECKING THE FUEL HOSES AND FUEL 
FILTER 

The following procedure applies to all of the fuel 
hoses. 

1. Remove: 

• seat 

• fuel tank 

2. Check: 

• fuel hose ® 
Cracks/damage -► Replace. 

•fuel filter © 
Damage/dirt -► Replace. 

NOTE: 

• Drain and flush the fuel tank if abrasive 
damage to any components of the fuel line 
is evident. 

3. Install: 

• fuel tank 

• seat 



3-24 



CHECKING THE CRANKCASE BREATHER HOSE/ 
CHECKING THE EXHAUST SYSTEM 




CHK 
ADJ 


<& 



EB303190 

CHECKING THE CRANKCASE BREATHER 
HOSE 

1. Remove: 

• seat 

• fuel tank 

• carburetor 

2. Check: 

• crankcase breather hose ® 
Cracks/damage -► Replace. 

Loose connection -► Connect properly. 

CAUTION: 

Make sure that the crankcase breather 
hose is routed correctly. 

3. Install: 

• carburetor 

• fuel tank 

• seat 





EB303200 

CHECKING THE EXHAUST SYSTEM 

The following procedure applies to all of the ex- 
haust pipes and gaskets. 

1. Check: 

• exhaust pipe ® 

• muffler® 
Cracks/damage -► Replace. 

• gasket ® 

Exhaust gas leaks -► Replace. 

2. Check: 

• tightening torque 



V 



Exhaust pipe ring nut (3) 

10Nm(1.0iTTkg) 
Exhaust pipe and footrest 
bracket ® 

20 Nm (2.0 nvkg) 
Exhaust pipe and muffler (D 

20 Nm (2.0 irrkg) 
Muffler and footrest bracket 
(rear) ® 

30 Nm (3.0 nrkg) 



3-25 



CHECKING THE COOLANT LEVEL/ 
CHECKING THE COOLING SYSTEM 



CHK 
ADJ 


«a 





EB303220 

CHECKING THE COOLANT LEVEL 

1 . Stand the motorcycle on a level surface. 

• Place the motorcycle on a suitable stand. 

• Make sure that the motorcycle is upright. 

2. Remove: 

• side cover (right) 

3. Check: 

• coolant level 

The coolant level should be between the 
maximum level mark® and minimum lev- 
el marks®. 

Below the minimum level mark — ► Add the 
recommended coolant to the proper level. 

CAUTION: 

• Adding water instead of coolant lowers 
the antifreeze content of the coolant. If 
water is used instead of coolant, check 
and correct the antifreeze concentra- 
tion of the coolant. 

• Use only distilled water. Soft water may 
be used if distilled water is not avail- 
able. 

4. Start the engine, warm it up for several min- 
utes, and then turn it off. 

5. Check: 

• coolant level 

NOTE: 

Before checking the coolant level, wait a few 
minutes until it settles. 

6. Install: 

• side cover (right) 

EB303230 

CHECKING THE COOLING SYSTEM 

1. Remove: 

• seat 

• fuel tank 

2. Check: 

• radiator ® 

• radiator inlet hose (2) 

• radiator outlet hose ® 

• water jacket outlet joint ® 

• water jacket inlet joint © 

• oil cooler inlet hose @ 

• oil cooler outlet hose (7) 
Cracks/damage -► Replace. 

Refer to "COOLING SYSTEM" in chapter 
5. 

3. Install: 

• fuel tank 

• seat 



3-26 



CHANGING THE COOLANT 




CHK 
ADJ 


<& 



EB303240 

CHANGING THE COOLANT 

1. Remove: 

• seat 

• fuel tank 

2. Disconnect: 

• coolant reservoir hose (D 

3. Drain: 

• coolant 

(from the coolant reservoir) 

4. Remove: 

• radiator cap 



A WARNING 



A hot radiator is under pressure. There- 
fore, do not remove the radiator cap 
when the engine is hot. Scalding hot fluid 
and steam may be blown out, which 
could cause serious injury. When the en- 
gine has cooled, open the radiator cap as 
follows: 

Place a thick rag or a towel over the radia- 
tor cap and slowly rotate the radiator cap 
counterclockwise towrd the detent to al- 
low any residual pressure to escape. 
When the hissing sound has stopped, 
press down on the radiator cap, while 
still pressing down turn it counterclock- 
wise, and then remove it. 

The following procedure applies to all of the 
coolant drain bolts and copper washers. 




5. Remove: 

• coolant drain bolt (water pump) ® 
(along with the copper washer) 

6. Drain: 

• coolant 

(from the engine and radiator) 

7. Check: 

• copper washer® (coolant drain bolt water 
pump) 

Damage -► Replace. 

8. Install: 

• coolant drain bolt (water pump) 



"^ 10Nm(1.0m-kg) 



3-27 



CHANGING THE COOLANT 




CHK 
ADJ 


«a 



9.Coonect: 

• coolant reservoir hose 

10. Fill: 

• cooling system 

(with the specified amount of the recom- 
mended coolant) 



11 



Recommended antifreeze 
High-quality ethylene glycol anti- 
freeze containing corrosion inhibi- 
tors for aluminum engines 

Mix ratio 
50% antifreeze/50 % water 



& 



Quantity 
Total amount 

1.95 L 
Coolant reservoir capacity 

0.61 L 
From minimum to maximum 
level mark 

0.22 L 



Handling notes for coolant 

Coolant is potentially harmful and should be 
handled with special care. 



A WARNING 



• If coolant splashes in your eyes, thor- 
oughly wash them with water and con- 
sult a doctor. 

• If coolant splashes on your clothes, 
quickly wash it away with water and 
then with soap and water. 

• If coolant is swallowed, induce vomit- 
ing and get immediate medical atten- 
tion. 

CAUTION: 



• Adding water instead of coolant lowers 
the antifreeze content of the coolant. If 
water is used instead of coolant, check, 
and if necessary, correct the antifreeze 
concentration of the coolant. 

• Use only distilled water. Soft water may 
be used if distilled water is not avail- 
able. 

• If coolant comes into contact with 
painted surfaces, immediately wash 
them with water. 

• Do not mix different types of antifreeze. 

Install: 

• radiator cap 



3-28 



CHANGING THE COOLANT 




CHK 
ADJ 


<& 



12. Fill: 

• coolant reservoir 

(with the recommended coolant to the 
maximum level mark®) 

13. Install: 

• coolant reservoir cap 

1 4. Start the engine, warm it up for several min- 
utes, and then turn if off. 

15. Check: 

• coolant level 

Refer to "CHECKING THE COOLANT 
LEVEL". 

NOTE: 

Before checking the coolant level, wait a few 
minutes until it settles. 

16. Install: 

• fuel tank 

• seat 



3-29 



ADJUSTING THE FRONT BRAKE/ 
ADJUSTING THE REAR BRAKE 




CHK 
ADJ 


«a 



CHASSIS 

ADJUSTING THE FRONT BRAKE 

1. Adjust: 
• brake lever position 
(distance (D from the throttle grip to the 
brake lever) 

a. While pushing the brake lever forward, 
turn the adjusting dial (D until the brake 
lever is in the desired position. 

NOTE: 

Be sure to align the setting on the adjusting 
dial with the arrow mark (2) 



Position #1 


Distance (a) is the 
largest. 


Position #4 


Distance ® is the 
smallest. 



A WARNING 



After adjusting the brake lever position, 
make sure that the pin on the brake lever 
holder is firmly inserted in the hole in the 
adjusting dial. 




EB304010 

ADJUSTING THE REAR BRAKE 

1. Check: 
• brake pedal position 
(distance ® from the top of the rider foot- 
rest to the top of the brake pedal) 
Out of specification -► Adjust. 




Brake pedal position (below 
the top of the rider footrest) 
36.6 mm 



2. Adjust: 
• brake pedal position 



a. Loosen the locknut ®. 

b. Turn the adjusting bolt ® in direction (a) or 
® until the specified brake pedal position 
is obtained. 



Direction (a) -► Brake pedal is raised. 



Direction (§)-► Brake pedal is lowered. 



3-30 



ADJUSTING THE REAR BRAKE/ 
CHECKING THE BRAKE FLUID LEVEL 



A WARNING 



CHK 
ADJ 


<& 



After adjusting the brake pedal position, 
check that the end of the adjusting bolt (D 
is visible through the hole ©. 

c. Tighten the locknut ® to specification. 



A WARNING 



A soft or spongy feeling in the brake ped- 
al can indicate the presence of air in the 
brake system. Before the vehicle is oper- 
ated, the air must be removed by bleed- 
ing the brake system. Air in the brake 
system will considerably reduce braking 
performance and could result in loss of 
control and possibly an accident. There- 
fore, inspect and, if necessary, bleed the 
brake system. 



CAUTION: 

After adjusting the brake pedal position, 
make sure that there is no brake drag. 



3. Adjust: 
• rear brake light switch 
Refer to "ADJUSTING THE REAR BRAKE 
LIGHT SWITCH". 





EB304020 

CHECKING THE BRAKE FLUID LEVEL 

1 . Stand the motorcycle on a level surface. 

NOTE: 

• Place the motorcycle on a suitable stand. 

• Make sure that the motorcycle is upright. 

2. Check: 

• brake fluid level 

Below the minimum level mark ® — ► Add 
the recommended brake fluid to the proper 
level. 



•tt 



Recommended brake fluid 
DOT4 



[A] Front brake 
\E Rear brake 



3-31 



CHECKING THE BRAKE FLUID LEVEL/ 
ADJUSTING THE REAR BRAKE LIGHT SWITCH 



A WARNING 



CHK 
ADJ 


«a 



• Use only the designated brake fluid. 
Other brake fluids may cause the rub- 
ber seals to deteriorate, causing leak- 
age and poor brake performance. 

• Refill with the same type of brake fluid 
that is already in the system. Mixing 
brake fluids may result in a harmful 
chemical reaction, leading to poor 
brake performance. 

• When refilling, be careful that water 
does not enter the reservoir. Water will 
significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock. 

CAUTION: 

Brake fluid may damage painted sur- 
faces and plastic parts. Therefore, al- 
ways clean up any spilt brake fluid im- 
mediately. 

NOTE: 

In order to ensure a correct reading of the 
brake fluid level, make sure that the top of 
the reservoir is horizontal. 



EB304050 

ADJUSTING THE REAR BRAKE LIGHT 
SWITCH 

NOTE: 




The rear brake light switch is operated by 
movement of the brake pedal. 
The rear brake light switch is properly ad- 
justed when the brake light comes on just 
before the braking effect starts. 

1. Check: 

• rear brake light operation timing 
Incorrect -► Adjust. 

2. Adjust: 

• rear brake light operation timing 

a. Hold the main body ® of the rear brake 
light switch so that it does not rotate and 
turn the adjusting nut ® in direction (a) or 
® until the rear brake light comes on at 
the proper time. 



Direction (a) 



Brake light comes 
on sooner. 



Direction (§) 



Brake light comes 
on later. 



3-32 



CHECKING THE BRAKE HOSES/ 
BLEEDING THE HYDRAULIC BRAKE SYSTEM 



CHK 
ADJ 


<& 



EB304062 

CHECKING THE BRAKE HOSES 

The following procedure applies to all of the 
brake hoses and clamps. 

1. Check: 

• brake hose 
Cracks/damage/wear -► Replace. 

2. Check: 

• brake hose clamp 

Loose connection — ► Tighten. 

3. Hold the motorcycle upright and apply the 
brake. 

4. Check: 

• brake hose 

Activate the brake several times. 

Brake fluid leakage -► Replace damaged 

hose. 

Refer to "FRONT AND REAR BRAKES" in 

chapter 7. 



BLEEDING THE HYDRAULIC BRAKE 
SYSTEM 



A WARNING 




Bleed the hydraulic brake system when- 
ever: 

• the system was disassembled, 

• a brake hose was loosened or removed, 

• the brake fluid level is very low, 

• brake operation is faulty. 

1. Remove: 

• reservoir cap 

• diaphragm (T) 

NOTE: 

• Be careful not to spill any brake fluid or al- 
low the brake master cylinder reservoir or 
brake fluid reservoir to overflow. 

• When bleeding the hydraulic brake sys- 
tem, make sure that there is always 
enough brake fluid before applying the 
brake. Ignoring this precaution could allow 
air to enter the hydraulic brake system, 
considerably lengthening the bleeding 
procedure. 

• If bleeding is difficult, it may be necessary 
to let the brake fluid settle for a few hours. 
Repeat the bleeding procedure when the 
tiny bubbles in the hose have disappeared. 



3-33 



BLEEDING THE HYDRAULIC BRAKE SYSTEM/ 
ADJUSTING THE SHIFT PEDAL 



CHK 
ADJ 


<a 



Front 




Rear 








r 


j 


<3>- 






^N 


~(2) 


^______ ■ ffhyl _ji \ 










// / ( v ~ 










2. Bleed: 
• hydraulic brake system 



a. Add the recommended brake fluid to the 
proper level. 

b. Install the diaphragm (brake master cylin- 
der reservoir or brake fluid reservoir). 

c. Connect a clear plastic hose ® tightly to 
the bleed screw®. 

d. Place the other end of the hose into a con- 
tainer. 

e. Slowly apply the brake several times. 

f. Fully squeeze the brake lever or fully de- 
press the brake pedal and hold it in posi- 
tion. 

g. Loosen the bleed screw. 

This will release the tension and cause 
the brake lever to contact the throttle grip 
of the brake pedal to fully extend. 

h. Tighten the bleed screw and then release 
the brake lever or brake pedal. 

i. Repeat steps (e) to (h) until all of the air 
bubbles have disappeared from the 
brake fluid in the plastic hose. 

j. Tighten the bleed screw to specification. 



% 



% 



Bleed screw 
6 Nm (0.6 rrrkg) 



Fill the reservoir to the proper level. 
Refer to "CHECKING THE BRAKE 
FLUID LEVEL". 



A WARNING 



After bleeding the hydraulic brake sys- 
tem, check the brake operation. 

EB304080 

ADJUSTING THE SHIFT PEDAL 

1. Check: 

• shift pedal position 

The end ® of the shift pedal is above the 
shift rod. (The angle ® should be approxi- 
mately 90°.) 
Incorrect -► Adjust. 

2. Adjust: 

• shift pedal position 

a. Loosen both locknuts (2). 

b. Turn the shift rod (3) in direction ® or © to 
obtain the correct shift pedal position. 



Direction (a) -► shift pedal is raised. 



Direction (§) -► pedal is lowered. 



Tighten both locknuts. 



3-34 



ADJUSTING THE DRIVE CHAIN SLACK 



CHK 
ADJ 


<& 



EB304090 

ADJUSTING THE DRIVE CHAIN SLACK 
NOTE: 



The drive chain slack must be checked at the 
tightest point on the chain. 




CAUTION: 

A drive chain that is too tight will over- 
load the engine and other vital parts, and 
one that is too loose can skip and dam- 
age the swingarm or cause an accident. 
Therefore, keep the drive chain slack 
within the specified limits. 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

NOTE: 

Both wheels should be on the ground with- 
out rider on the motorcycle. 

2. Rotate the rear wheel several times and 
check the drive chain to locate its tightest 
point. 

3. Check: 

• drive chain slack (a) 
Out of specification -+ Adjust. 




Drive chain slack 
30 ~ 40 mm 



4. Loosen: 

• wheel axle nut ® 

5. Adjust: 

• drive chain slack 



a. Loosen both locknuts®. 

b. Turn both adjusting nuts (2) in direction (a) 
or® until the specified drive chain slack 
is obtained. 



Direction (a) - 


+ Drive chain is 
tightened. 


Direction (§)- 


► Drive chain is 
loosened. 


NOTF- 



To maintain the proper wheel alignment, 

adjust both sides evenly. 

Push the rear wheel forward to make sure 

that there is no clearance between the 

swingarm end plates and the ends of the 

swingarm. 



3-35 



ADJUSTING THE DRIVE CHAIN SLACK/LUBRICATING THE 
DRIVE CHAIN/CHECKING AND ADJUSTING THE STEERING HEAD 



CHK 
ADJ 


«a 



c. Tighten the wheel axle nut to specifica- 
tion. 



V 



Wheel axle nut 
117 Nm (11.7 nvkg) 



Locknut 
16Nm(1.6m»kg) 



EB304100 

LUBRICATING THE DRIVE CHAIN 

The drive chain consists of many interacting 
parts. If the drive chain is not maintained proper- 
ly, it will wear out rapidly. 
Therefore, the drive chain should be serviced, 
especially when the motorcycle is used in dusty 
areas. This motorcycle has a drive chain with 
small rubber O-rings between each side plate. 
Steam cleaning, high-pressure washing, certain 
solvents, and the use of a coarse brush can 
damage these O-rings. Therefore, use only ker- 
osine to clean the drive chain. Wipe the drive 
chain dry and thoroughly lubricate it with engine 
oil or chain lubricant that is suitable for O-ring 
chains. Do not use any other lubricants on the 
drive chain since they may contain solvents that 
could damage the O-rings. 



Recommended lubricant 
Engine oil or chain lubricant suitable 
for O-ring chains 



EB304130 

CHECKING AND ADJUSTING THE 
STEERING HEAD 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

NOTE: 

Place the motorcycle on a suitable stand so 
that the front wheel is elevated. 




2. Check: 
• steering head 
Grasp the bottom of the front fork legs and 
gently rock the front fork. 
Looseness or binding -► Adjust the steer- 
ing head. 



3. Remove: 

• handlebar 

• upper bracket 



3-36 



CHECKING AND ADJUSTING THE STEERING HEAD 



4. Adjust: 
• steering head 




CHK 
ADJ 


<& 




a. Remove the lock washer (D, the upper 
ring nut ®, and the rubber washer ®. 

b. Loosen the lower ring nut ® and then 
tighten it to specification with a ring nut 
wrench (§). 

NOTE: 

Set the torque wrench at a right angle to the 
ring nut wrench. 




Ring nut wrench 
90890-01403 



X 



Lower ring nut 
(initial tightening torque) 
52 Nm (5.2 nvkg) 



c. Loosen the lower ring nut completely, 
then tighten it to specification. 



A WARNING 



Do not overtighten the lower ring nut. 



X 



Lower ring nut 
(final tightening torque) 
18 Nm (1.8 nvkg) 



d. Check the steering head for looseness or 
binding by turning the front fork all the 
way in both directions. If any binding is 
felt, remove the lower bracket and inspect 
the upper and lower bearings. 

Refer to "STEERING HEAD AND HAN- 
DLEBAR" in chapter 7. 

e. Install the rubber washer (§)■ 

f. Install the upper ring nut (7). 

g. Finger tighten the upper ring nut (7), then 
align the slots of both ring nuts. If neces- 
sary, hold the lower ring nut and tighten 
the upper ring nut until their slots are 
aligned. 

h. Install the lock washer (§)■ 

NOTE: 

Make sure that the lock washer tabs ® sit 
correctly in the ring nut slots ®. 



3-37 



CHECKING ADJUSTING THE STEERING HEAD/CHECKING THE FRONT 
FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 

5. Install: 

• upper bracket 

• handlebar 



CHK 
ADJ 


«a 



V 



Steering stem nut 

110 Nm (11.0 nvkg) 
Upper bracket pinch bolt 

30 Nm (3.0 nvkg) 
Handlebar upper holder bolt 

23 Nm (2.3 nvkg) 



EB304140 

CHECKING THE FRONT FORK 

1 . Stand the motorcycle on a level surface. 



A WARNING 




Securely support the motorcycle so that 
there is no danger of it falling over. 

2. Check: 

• inner tube 
Damage/scratches -► Replace. 

• oil seal 

Oil leakage -► Replace. 

3. Hold the motorcycle upright and apply the 
front brake. 

4. Check: 

• operation 

Push down hard on the handlebar several 

times and check if the front fork rebounds 

smoothly. 

Unsmooth operation -► Repair. 

Refer to "FRONT FORK" in chapter 7. 



EB304160 

ADJUSTING THE REAR SHOCK ABSORBER 
ASSEMBLY 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

Spring preload 
CAUTION: 



Never go beyond the maximum or mini- 
mum adjustment positions. 

1. Adjust: 
• spring preload 

NOTE: 

Adjust the spring preload with the special 
wrench and extension bar included in the 
owner's tool kit. 



3-38 



ADJUSTING THE REAR SHOCK ABSORBER 
ASSEMBLY/CHECKING THE TIRES 




CHK 
ADJ 


<& 



a. Turn the adjusting ring (D in direction (a) or 

©. 

b. Align the desired position on the adjusting 
ring with the stopper. 



Direction (a) 



Spring preload is 
increased (suspension 
is harder). 



Direction (§)- 



Spring preload is 
decreased (suspension 
is softer). 





Minimum 


Standard 


Maximum 


Adjusting 
positions 


1 


4 


9 




EB304170 

CHECKING THE TIRES 

The following procedure applies to both of the 
tires. 
1. Measure: 
• tire pressure 
Out of specification -► Regulate. 



A WARNING 



• The tire pressure should only be 
checked and regulated when the tire 
temperature equals the ambient air 
temperature. 

• The tire pressure and the suspension 
must be adjusted according to the total 
weight (including cargo, rider passen- 
ger and accessories) and the antici- 
pated riding speed. 

• Operation of an overloaded motorcycle 
could cause tire damage, an accident 
or an injury. 

NEVER OVERLOAD THE MOTORCYCLE. 



3-39 



CHECKING THE TIRES 



CHK 
ADJ 


«a 



Basic weight 
(with oil and a 
full fuel tank) 


210 kg 


Maximum load 


187 kg 


Cold tire 
pressure 


Front tire 


Rear tire 


Up to 90 kg load* 


225 kPa 

(2.25 
kg /cm 2 ) 


250 kPa 

(2.50 
kg/cm 2 ) 


90 kg maximum 
load* 


225 kPa 

(2.25 
kg /cm 2 ) 


280 kPa 

(2.80 
kg/cm 2 ) 


High speed 
riding 


225 kPa 

(2.25 
kg /cm 2 ) 


280 kPa 

(2.80 
kg/cm 2 ) 



total of cargo, 
accessories 



A WARNING 



rider, passenger and 




It is dangerous to ride with a worn-out 

tire. 

When the tire tread reaches the wear 

limit, replace the tire immediately. 



2. Check: 
• tire surface 
Damage/wear 



Replace the tire. 




Minimum tire tread depth 
1.6 mm 



© Tire tread depth 

(2) Side wall 

(3) Wear indicator 



A WARNING 




12011003 



• Do not use a tubeless tire on a wheel de- 
signed only for tube tires to avoid tire 
failure and personal injury from sudden 
deflation. 

• When using a tube tire, be sure to install 
the correct tube. 

• Always replace a new tube tire and a 
new tube as a set. 

• To avoid pinching the tube, make sure 
that the wheel rim band and tube are 
centered in the wheel groove. 

• Patching a punctured tube is not rec- 
ommended. If it is absolutely neces- 
sary to do so, use great care and re- 
place the tube as soon as possible with 
a good quality replacement. 

fflTire H Wheel 



Tube wheel 


Tube tire only 


Tubeless wheel 


Tube or tubeless 
tire 



3-40 



CHECKING THE TIRES/ 
CHECKING THE WHEELS 



CHK 
ADJ 


<& 



• After extensive tests, the tires listed be- 
low have been approved by Yamaha 
Motor Co., Ltd. for this model. The front 
and rear tires should always be by the 
same manufacturer and of the same de- 
sign. No guarantee concerning han- 
dling characteristics can be given if a 
tire combination other than one ap- 
proved by Yamaha is used on this mo- 
torcycle. 

Front tire 



Manufacturer 


Size 


Type 


BRIDGESTONE 


110/70-ZR17 
(54 W) 


BT57F 


DUNLOP 


110/70-ZR17 
(54 W) 


D207F 



Rear tire 




Manufacture 


Size 


Type 


BRIDGESTONE 


160/60-ZR17 
(69 W) 


BT57R 


DUNLOP 


160/60-ZR17 
(69 W) 


D207J 



A WARNING 



After mounting a new tire, ride conserva- 
tively for a while to become accustomed 
to the "feel" of the new tire and to allow 
the tire to seat itself properly in the rim. 
Failure to do so could lead to an accident 
with possible injury to the rider or dam- 
age to the motorcycle. 

NOTE: 

For tires with a direction of rotation mark ® : 
• Install the tire with the mark printing in the 
direction of wheel rotation. 



EB304180 

CHECKING THE WHEELS 

The following procedure applies to both of the 
wheels. 
1. Check: 
• wheel 
Damage/out-of-round -► Replace. 



A WARNING 



Never attempt to make any repairs to the 
wheel. 

NOTE: 

After a tire or wheel has been changed or re- 
placed, always balance the wheel. 



3-41 



CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE 

LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/ LUBRICATING 

THE CENTER STAND/ LUBRICATING THE REAR SUSPENSION 



CHK 
ADJ 


«a 



EB304200 

CHECKING AND LUBRICATING THE 
CABLES 

The following procedure applies to all of the 
cable sheaths and cables. 



A WARNING 



Damaged cable sheaths may cause the 
cable to corrode and interfere with its 
movement. Replace damaged cable 
sheaths and cables as soon as possible. 

1. Check: 

• cable sheath 
Damage -► Replace. 

2. Check: 

• cable operation 

Unsmooth operation -► Lubricate. 




Recommended lubricant 
Engine oil or a suitable cable 
lubricant 



NOTE: 

Hold the cable end upright and pour a few 
drops of lubricant into the cable sheath or 
use a suitable lubing device. 



DB304210 

LUBRICATING THE LEVERS AND PEDALS 

Lubricate the pivoting point and metal-to-metal 
moving parts parts of the levers and pedals. 



Recommended lubricant 
Lithium soap base grease 



EB304220 

LUBRICATING THE SIDESTAND 

Lubricate the pivoting point and metal-to-metal 
moving parts of the sidestand. 



Recommended lubricant 
Lithium soap base grease 



LUBRICATING THE CENTER STAND 

Lubricate the pivoting point and metal-to-metal 
moving parts of the center stand. 



Recommended lubricant 
Lithium soap base grease 



EB304240 

LUBRICATING THE REAR SUSPENSION 

Lubricate the pivoting point and metal-to-metal 
moving parts of the rear suspension. 



Recommended lubricant 
Molybdenum disulfide grease 



3-42 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<& 



ELECTRICAL SYSTEM 

CHECKING AND CHARGING THE BATTERY 



A WARNING 




Batteries generate explosive hydrogen 
gas and contain electrolyte which is 
made of poisonous and highly caustic 
sulfuric acid. 

Therefore, always follow these preven- 
tive measures: 

• Wear protective eye gear when han- 
dling or working near batteries. 

• Charge batteries in a well-ventilated 
area. 

• Keep batteries away from fire, sparks or 
open flames (e.g., welding equipment, 
lighted cigarettes). 

• DO NOT SMOKE when charging or han- 
dling batteries. 

• KEEP BATTERIES AND ELECTROLYTE 
OUT OF REACH OF CHILDREN. 

• Avoid bodily contact with electrolyte as 
it can cause severe burns or permanent 
eye injury. 

First aid in case of bodily contact: 
External 

• SKIN - Wash with water. 

• EYES - Flush with water for 1 5 minutes 
and get immediate medical attention. 

Internal 

Drink large quantities of water or milk fol- 
lowed with milk of magnesia, beaten egg 
or vegetable oil. Get immediate medical 
attention. 

CAUTION: 



• This is a sealed battery. Never remove 
the sealing caps because the balance 
between cells will not be maintained 
and battery performance will deterio- 
rate. 

• Charging time, charging amperage and 
charging voltage for a MF battery are 
different from those of conventional 
batteries. The MF battery should be 
charged as explained in the charging 
method illustrations. If the battery is 
overcharged, the electrolyte level will 
drop considerably. 

Therefore, take special care when 
charging the battery. 



3-43 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


«a 












Volt meter 


1 12.50V | 


e^ 


A 










i® 




^n^iLt"^ 




18350601 



Relationship between the open-circuit voltage 
and the charging time at 20°C (68°F) 




5 6.5 10 
Charging time (hours) 
■ This varies depending on the temperature, the state of charge 
in the battery plates and the electrolyte tevel. 



14 
Sl3 

> 

111 












Ambient 
temperature 
20°C (68 C F) 


















i 


i 








i 
i 


i 
i 








i 


i 




100 75 50 30 25 20 

Condition of the charge in the battery (%) 



NOTE: 

Since MF batteries are sealed, it is not pos- 
sible to check the charge state of the battery 
by measuring the specific gravity of the elec- 
trolyte. Therefore, the charge of the battery 
has to be checked by measuring the voltage 
at the battery terminals. 

1. Remove: 

• seat 

2. Disconnect: 

• battery leads 

(from the battery terminals) 

CAUTION: 



First, disconnect the negative lead (D, 
then the positive lead (2). 

3. Remove: 

• battery 

4. Check: 

• battery charge 

a. Connect a digital voltmeter to the battery 
terminals. 



Tester positive 
lead 


battery positive 
terminal 


Tester negative 
lead 


battery negative 
terminal 



NOTE: 

• The charge state of a MF battery can be 
checked by measuring its open-circuit volt- 
age (i.e., the voltage when the positive ter- 
minal is disconnected). 

• No charging is necessary when the open- 
circuit voltage equals or exceeds 12.8 V. 

b. Check the charge of the battery, as 
shown in the charts and the following ex- 
ample. 

Example 

c. Open-circuit voltage = 12.0 V 

d. Charging time = 6.5 hours 

e. Charge of the battery = 20-30 % 

5. Charge: 

• battery 

(refer to the appropriate charging method 
illustration) 



3-44 



CHECKING AND CHARGING THE BATTERY 



A WARNING 



CHK 
ADJ 


<& 



Do not quick charge a battery. 



Charging 






Ambient temperature 


s 18 

» 17 






































































I 13 

°10 


























































10 20 30 40 50 60 Time (minutes) 
L^» Check the open-circuit 
voltage 



A WARNING 



Make sure that the battery vent is free of 
obstructions. 

Never remove the MF battery sealing 
caps. 

Do not use a high-rate battery charger. 
They force a high-amperage current 
into the battery quickly and can cause 
battery overheating and battery plate 
damage. 

If it is impossible to regulate the charg- 
ing current on the battery charger, be 
careful not to overcharge the battery. 
When charging a battery, be sure to re- 
move it from the motorcycle. (If charg- 
ing has to be done with the battery 
mounted on the motorcycle, discon- 
nect the negative lead from the battery 
terminal.) 

To reduce the chance of sparks, do not 
plug in the battery charger until the bat- 
tery charger leads are connected to the 
battery. 

Before removing the battery charger 
lead clips from the battery terminals, be 
sure to turn off the battery charger. 
Make sure that the battery charger lead 
clips are in full contact with the battery 
terminal and that they are not shorted. 
A corroded battery charger lead clip 
may generate heat in the contact area 
and a weak clip spring may cause 
sparks. 

If the battery becomes hot to the touch 
at any time during the charging pro- 
cess, disconnect the battery charger 
and let the battery cool before recon- 
necting it. Hot batteries can explode! 
As shown in the following illustration, 
the open-circuit voltage of a MF battery 
stabilizes about 30 minutes after charg- 
ing has been completed. Therefore, 
wait 30 minutes after charging is com- 
pleted before measuring the open-cir- 
cuit voltage. 



3-45 



CHECKING AND CHARGING THE BATTERY 

Charging method using a variable-current (voltage) type charger 



CHK 
ADJ 


«a 



Measure the open-circuit 
voltage prior to charging. 



Charger 



AMP meter 




I 



YES 



Connect a charged and 
AMP meter to the battery 
and start charging. 



NOTE: 

Voltage should be measured 30 
minutes after the machine is stopped. 



NOTE: 



Make sure that the current 
is higher than the standard 
charging current written on 
the battery. 



Set the charging voltage at 1 6 ~ 1 7 V 
(If the setting is lower, charging will be 
insufficient. If too high, the battery will 
be over-charged.) 



NO 



By turning the charging 
voltage adjust dial, set the 
charging voltage at 20 ~ 24 V. 



Adjust the voltage so that the 
current is at the standard 
charging level. 



YES 



I 



Monitor the amperage for 
3 — 5 minutes to check if the 
standard charging current is 
reached. 



Set the time according to the 
charging time suitable for the 
open-circuit voltage. 
Refer to "Battery condition 
checking steps". 



NO 



If the current does not 
exceed the standard 
charging current after 5 
minutes, replace the battery. 



If charging requires more than 5 hours, it is advisable to check the 
charging current after a lapse of 5 hours. If there is any change in the 
amperage, readjust the voltage to obtain the standard charging 
current. 



i 



Measure the battery open-circuit voltage after leaving the battery 
unused for more than 30 minutes. 
12.8 V or more — Charging is complete. 
12.7 V or less — Recharging is required. 
Under 12.0 V — Replace the battery. 



3-46 



CHECKING AND CHARGING THE BATTERY 

Charging method using a constant-voltage type charger 



CHK 
ADJ 


<& 



Measure the open-circuit 
voltage prior to charging. 



NOTE: 

Voltage should be measured 30 
minutes after the machine is stopped. 



Connect a charger and 
AMP meter to the battery 
and start charging. 



YES 



Make sure that the current 
is higher than the standard 
charging current written on 
the battery. 



NO 



Charge the battery until the battery's 
charging voltage is 15 V. Charge the 
battery until the battery's charging 
voltage is 15 V. 



This type of battery charger cannot 
charge the MF battery. A variable 
voltage charger is recommended. 



NOTE: 

Set the charging time at 20 hours 
(maximum). 



Measure the battery open-circuit 

voltage after leaving the battery 

unused for more than 30 minutes. 

12.8 V or more — Charging is 

complete. 

12.7 V or less — Recharging is 

required. 

Under 1 2.0 V — Replace the battery. 



Charger 



AMP meter 




Charging method using a constant-current type charger 

This type of battery charger cannot charge the MF battery. 



3-47 



CHECKING AND CHARGING THE BATTERY/ 

CHECKING THE FUSES 



6. Install: 

• battery 

7. Connect: 

• battery leads 

(to the battery terminals) 




CHK 
ADJ 


«a 




CAUTION: 

First, connect the positive lead CD, then 
the negative lead (2). 

8. Check: 

• battery terminals 

Dirt — ► Clean with a wire brush. 
Loose connection -► Connect properly. 

9. Lubricate: 

• battery terminals 



Recommended lubricant 
Dielectric grease 



10. Install: 

• seat 

EB305040 

CHECKING THE FUSES 

The following procedure applies to all of the 
fuses. 

CAUTION: 

To avoid a short circuit, always turn the 
main switch to "OFF" when checking or 
replacing a fuse. 

1. Remove: 

• seat 

2. Check: 

• fuse 

a. Connect the pocket tester to the fuse and 
check it for continuity. 

NOTE: 

Se the pocket tester selector to "£l x 1 ". 




Pocket tester 
96890-03112 



b. If the pocket tester indicates "«>", replace 
the fuse. 



3-48 



CHECKING THE FUSES/ 
REPLACING THE HEADLIGHT BLUBS 

3. Replace: 
• blown fuse 



CHK 
ADJ 


<& 



a. Turn off the ignition. 

b. Install a new fuse of the correct amperage 
rating. 

c. Turn on the switches to verify if the electri- 
cal circuit is operational. 

d. If the fuse immediately blows again, 
check the electrical circuit. 




Fuses 


Amperage 
rating 


Quantity 


Main fuse 


30 A 




Headlight fuse 


20 A 




Signaling 
system fuse 


20 A 




Ignition fuse 


20 A 




Radiator 
fan fuse 


5A 




Reserve fuse 


30 A 




20 A 




10A 





A WARNING 



Never use a fuse with an amperage rating 
other than that specified. Improvising or 
using a fuse with the wrong amperage 
rating may cause extensive damage to 
the electrical system, cause the lighting 
and ignition systems to malfunction and 
could possibly cause a fire. 

4. Install: 
• seat 



REPLACING THE HEADLIGHT BULBS 

The following procedure applies to both of the 
headlight bulbs. 
1 . Disconnect: 
• headlight lead ® 



3-49 



REPLACING THE HEADLIGHT BULBS/ 
ADJUSTING THE HEADLIGHT BEAMS 



2. Remove: 

• headlight bulb holder© 

3. Remove: 

• headlight bulb© 




CHK 
ADJ 


«a 



A WARNING 



Since the headlight bulb gets extremely 
hot, keep flammable products and your 
hands away from the bulb until it has 
cooled down. 

4. Install: 

• headlight bulb (New) 

Secure the new headlight bulb with the 
headlight bulb holder. 

CAUTION: 

Avoid touching the glass part of the 
headlight bulb to keep it free from oil, 
otherwise the transparency of the glass, 
the life of the bulb and the luminous flux 
will be adversely affected. If the headlight 
bulb gets soiled, thoroughly clean it with 
a cloth moistened with alcohol or lacquer 
thinner. 

5. Install: 

• headlight bulb holder 

6. Connect: 

• headlight lead 




ADJUSTING THE HEADLIGHT BEAMS 

The following procedure applies to both of the 
headlights. 
1. Adjust: 
• headlight beam (vertically) 

a. Turn the adjusting screw® ® in direction 
®or®. 



Direction (a) 



Direction (§) 



Headlight beam is 
raised. 



Headlight beam is 
lowered. 



3-50 



ADJUSTING THE HEADLIGHT BEAMS 



CHK 
ADJ 


<& 



2. Adjust: 
• headlight beam (horizontally) 

a. Turn the adjusting knob (2) (?) in direction 
(Dor®. 
Left headlight @ 



Direction (a) 



Headlight beam 
moves to the right. 



Direction (§) 



Headlight beam 
moves to the left. 



Right headlight® 



Direction (a) 



Headlight beam 
moves to the left. 



Direction (§) 



Headlight beam 
moves o the right. 



3-51 



CHK 
ADJ 


«a 




CHAPTER 4 
OVERHAULING THE ENGINE 

REMOVING THE ENGINE 4-1 

DRIVE SPROCKET AND EXHAUST PIPE 4-1 

LEADS AND HOSES 4-3 

ENGINE BRACKET AND ENGINE 4-4 

INSTALLING THE ENGINE 4-5 

CAMSHAFT 4-6 

CYLINDER HEAD COVERS 4-6 

CAMSHAFTS 4-7 

REMOVING THE CAMSHAFTS 4-8 

CHECKING THE CAMSHAFTS 4-9 

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, 

AND TIMING CHAIN GUIDES 4-10 

CHECKING THE TIMING CHAIN TENSIONER 4-11 

INSTALLING THE CAMSHAFTS 4-11 

CYLINDER HEAD 4-14 

REMOVING THE CYLINDER HEADS 4-15 

CHECKING THE CYLINDER HEADS 4-15 

INSTALLING THE CYLINDER HEAD 4-16 

VALVES AND VALVE SPRINGS 4-17 

REMOVING THE VALVES 4-18 

CHECKING THE VALVES AND VALVE GUIDES 4-19 

CHECKING THE VALVE SEATS 4-20 

CHECKING THE VALVE SPRINGS 4-22 

CHECKING THE VALVE LIFTERS 4-22 

CHECKING THE CAMSHAFT CAP 4-23 

INSTALLING THE VALVES 4-23 

CYLINDERS AND PISTONS 4-25 

REMOVING THE CYLINDERS AND PISTONS 4-26 

CHECKING THE CYLINDERS AND PISTONS 4-26 

CHECKING THE PISTON RINGS 4-27 

CHECKING THE PISTON PINS 4-28 

INSTALLING THE PISTON AND CYLINDER 4-29 

CLUTCH 4-31 

CLUTCH COVER 4-31 

CLUTCH 4-32 

REMOVING THE CLUTCH 4-34 

CHECKING THE FRICTION PLATES 4-34 

CHECKING THE CLUTCH PLATES 4-34 

CHECKING THE CLUTCH SPRINGS 4-35 

CHECKING THE CLUTCH SPRING PLATE 4-35 

CHECKING THE CLUTCH HOUSING 4-35 

CHECKING THE CLUTCH BOSS 4-36 

CHECKING THE PRESSURE PLATE 4-36 

CHECKING THE CLUTCH PUSH RODS 4-36 

INSTALLING THE CLUTCH 4-36 

SHIFT SHAFT 4-39 

CHECKING THE SHIFT SHAFT 4-40 

INSTALLING THE SHIFT SHAFT 4-40 




AC MAGNETO AND STARTER CLUTCH 4-41 

STATOR COIL 4-41 

STARTER CLUTCH 4-42 

AC MAGNETO ROTOR 4-43 

REMOVING THE STARTER CLUTCH 4-44 

REMOVING THE AC MAGNETO 4-44 

CHECKING THE STARTER CLUTCH 4-45 

INSTALLING THE AC MAGNETO 4-46 

INSTALLING THE STARTER CLUTCH 4-46 

OIL PAN AND OIL STRAINER 4-47 

OIL STRAINER 4-47 

OIL PUMP 4-48 

REMOVING THE OIL PAN 4-50 

CHECKING THE OIL PUMP 4-50 

CHECKING THE RELIEF VALVE 4-50 

CHECKING THE OIL STRAINER 4-51 

CHECKING THE OIL NOZZLE 4-51 

ASSEMBLING THE OIL PUMP 4-51 

INSTALLING THE OIL PUMP 4-52 

INSTALLING THE OIL STRAINER 4-52 

INSTALLING THE OIL PAN 4-52 

CRANKCASE 4-54 

DISASSEMBLING THE CRANKCASE 4-56 

CHECKING THE CRANKCASE 4-56 

ASSEMBLING THE CRANKCASE 4-57 

CRANKSHAFT 4-59 

CONNECTING ROD 4-60 

REMOVING THE CRANKSHAFT ASSEMBLY 4-61 

REMOVING THE CONNECTING RODS 4-61 

CHECKING THE CRANKSHAFT AND CONNECTING RODS 4-61 

INSTALLING THE CONNECTING RODS 4-66 

INSTALLING THE CRANKSHAFT 4-68 

TRANSMISSION 4-69 

CHECKING THE TRANSMISSION 4-72 

INSTALLING THE TRANSMISSION 4-73 

SHIFT DRUM AND SHIFT FORKS 4-74 

CHECKING THE SHIFT FORKS 4-75 

CHECKING THE SHIFT DRUM ASSEMBLY 4-75 

INSTALLING THE SHIFT FORKS AND SHIFT DRUM 

ASSEMBLY 4-75 



REMOVING THE ENGINE 



OVERHAULING THE ENGINE 
REMOVING THE ENGINE 

DRIVE SPROCKET AND EXHAUST PIPE 




^ 10Nm(1.0nvkg) 



3 K 



17Nm(1.7m-kg) 



70 Nm (7.0 nrkg) 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the drive sprocket and 




Remove the parts in the order listed. 




exhaust pipe 








Drain the coolant 








Drain the engine oil 




Refer to "CHANGING THE ENGINE OIL" 
section in capter 3. 




Front cowling 




" Refer to "FRONT COWLING/SEAT/ 
SIDE COVER/FUEL TANK" section in 




Fuel tank 




_ chapter 3. 




Battery negative terminal 








Radiator 




Refer to "RADIATOR" section in chapter 5. 




Carburetor 




Refer to "CARBURETOR" section in 
chapter 6. 




Starter motor 




Refer to "STARTER MOTOR" section in 
chapter 8. 


1 


Exhaust pipe assembly 


1 




2 


Exhaust pipe gasket 


4 




3 


Oil filter 


1 





4-1 



REMOVING THE ENGINE 




"^ 10Nm(1.0nvkg) 



17Nm(1.7m-kg) 



70 Nm (7.0 nrkg) 




*\" 10 Nm (1.0 nrkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


4 


Shift arm 


1 


Refer to "INSTALLING THE ENGINE" 


5 


Drive sprocket cover 


1 


section. 


6 


Drive chain sprocket gasket 


1 




7 


Dowel pin 


2 




8 


Lock washer 


1 




9 


Drive sprocket/ Drive chain 


1/1 


For installation, reverse the removal 
procedure. 



4-2 



LEADS AND HOSES 



REMOVING THE ENGINE 




Engine right side 



Engine left side 




12Nm(1.2m«kg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


1 


Disconnecting the leads and hoses 

Magneto/sidestand/neutral/engineoil 
level switch lead 


l/l/l/l 


Disconnect the parts in the order listed. 


2 


Ground lead 


1 




3 

4 


Plug cap 

Crankcase breather hose 


4 
1 




5 


Cover 


1 




6 


Water pump outlet hose 


1 




7 


Radiator outlet hose 


1 




8 


Engine outlet hose 


1 




9 


Engine outlet hose 


1 


For connecting, reverse the disconnection 
procedure. 



4-3 



REMOVING THE ENGINE 



ENGINE BRACKET AND ENGINE 





^ 33 Nm (3.3 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the engine bracket and 




Remove the parts in the order listed. 




engine 






1 


Engine mounting bolt (front left) 






2 


Engine mounting bolt (front right) 






3 


Engine bracket (front) 






4 


Engine mounting bolt (rear upper) 




Refer to "INSTALLING THE ENGINE" 


5 


Engine bracket (rear right) 




section. 


6 


Engine mounting bolt (rear lower) 






7 


Engine 




For installation, reverse the removal 
procedure. 



4-4 



REMOVING THE ENGINE 




% 




\ ^ 




fxjSVj^ 






^fttlSl} 


mi) 


©-. 


\V\^^y1t? 


In 




"^l'v )J/P 


few 




^>crf£> 


M 


CD" 




V^- !' 


T W 


UJ 








\£/ 





EB400700 

INSTALLING THE ENGINE 

1. Install: 

• bolt © 

• bolt (2) 

• bolt © 

• bolt ® 

• engine bracket © 

• engine bracket © 

NOTE: 



Do not fully tighten the bolts. 



2. Tighten the bolts in the following order. 





Bolt® 


55 Nm (5.5 m*kg) 


BOIll^J 


55 Nm (5.5 m*kg) 


Bolt© 


55 Nm (5.5 m*kg) 


Bolt® 


55 Nm (5.5 m*kg) 


Engine bracket © 


33 Nm (3.3 m«kg) 


Engine bracket © 


10Nm(10nvkg) 



3. Install: 
• shift arm ® 

NOTE: 



• Align the punch mark (a) in the shift shaft 
with the slot in the shift arm. 

• Align the bottom edge of the shift pedal © 
with the mark® on the frame-to-swingarm 
bracket. 



V 



Shift arm bolt 
10Nm(1.0nvkg) 



4-5 



CAMSHAFT 

CYLINDER HEAD COVERS 



CAMSHAFT 




10Nm(1.0nrkg) 




"^ 9 Nm (0.9 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the cylinder head cover 

Front cowling 




Remove the parts in the order listed. 

- Refer to "FRONT COWLING/SEAT/ 

SIDE COVER/FUEL TANK" section 




Seat and fuel tank 




-I in chapter 3. 




Drain the coolant 








Radiator 




Refer to "RADIATOR" section in chapter 5. 




Carburetor 




Refer to "CARBURETOR" section in 




Exhaust pipe 




chapter 6. 
n Refer to "REMOVING THE ENGINE" 


1 
2 
3 


Plug cap 

Cylinder head side cover 
Cylinder head cover 
Cylinder head cover gasket 


4 
1 
1 


_ section. 

For installation, reverse the removal 
procedure. 



4-6 



CAMSHAFT 



CAMSHAFT 




10Nm(1.0nvkg) 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the camshafts 




Remove the parts in the order listed. 


1 


Spark plug 


4 




2 


Magneto cover 


1 




3 


Timing chain guide (upper) 


1 




4 


Timing chain tensioner assembly 


1 




5 


Timing chain guide (exhaust side) 


1 


Refer to "REMOVING/INSTALLING THE 


6 


Camshaft cap 


4 


CAMSHAFT" section. 


7 


Dowel pin 


12 




8 


Camshaft (intake) 


1 




9 


Cmashaft (exhaust) 


1 




10 


Camshaft sprocket 


2 - 


For installation, reverse the removal 
procedure. 



4-7 



CAMSHAFT 





EB401102 

REMOVING THE CAMSHAFTS 

1. Remove: 

• magneto cover 

2. Align: 

• "T" mark on the magneto rotor 

(with the stationary pointer on the crank- 
case) 

a. Turn the crankshaft counterclockwise. 

b. When piston #1 is at TDC on the com- 
pression stroke, align the "T" mark® with 
the stationary pointer ®. 

NOTE: 

TDC on the compression stroke can be 
found when the camshaft lobes are turned 
away from each other. 





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3. Remove: 

• timing chain guide (top side) ® 

4. Loosen: 

• camshaft sprocket bolts ® 




5. Loosen: 

• timing chain tensioner cap bolt ® 

6. Remove: 

• timing chain tensioner® 



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7. Remove: 

• timing chain guide (exhaust side) ® 

• camshaft caps (D 

NOTE: 



For reference during installation, put identifi- 
cation marks on each camshaft cap. 



4-8 




CAMSHAFT 




CAUTION: 

To prevent damage to the cylinder head, 
camshafts or camshaft caps, loosen the 
camshaft cap bolts in stages and in a 
crisscross pattern, working from the out- 
side in. 

. Remove: 

• intake camshaft ® 

• exhaust camshaft © 

NOTE: 

To prevent the timing chain from falling into 
the crankcase, fasten it with a wire ®. 



w® il liiiljl ^ If- |L1[-|1 <& IB 












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EB401401 

CHECKING THE CAMSHAFTS 

1. Check: 
• camshaft lobes 
Blue discoloration/pitting/scratches 
Replace the camshaft. 















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n 


A 


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B 






2. Measure: 
• camshaft lobe dimensions A and B 
Out of specification -+ Replace the cam- 
shaft. 




Camshaft lobe dimension limit 
Intake 

@ 32.7 mm 

® 24.95 mm 
Exhaust 

@ 32.4mm 

® 24.9 mm 



3. Measure: 
• camshaft runout 
Out of specification 



Replace. 




Camshaft runout 
Less than 0.03 mm 



4-9 



CAMSHAFT 





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y © ^ 




12560103 




4. Measure: 
• camshaft-journal-to-camshaft-cap clear- 
ance 

Out of specification -► Measure the cam- 
shaft journal diameter. 




Camshaft-journal-to- 
camshaft-cap clearance 
0.08 mm 



a. Install the camshaft into the cylinder head 
(without the dowel pins and camshaft 
caps). 

b. Position a strip of Plastigauge® © onto 
the camshaft journal as shown. 

c. Install the dowel pins and camshaft caps. 

NOTE: 

• Tighten the camshaft cap bolts in stages 
and in a crisscross pattern, working from 
the inner caps out. 

• Do not turn the camshaft when measuring 
the camshaft journal-to-camshaft cap 
clearance with the Plastigauge®. 



Camshaft cap bolt 
10Nm(1.0irrkg) 



a. Remove the camshaft caps and then 
measure the width of the Plastigauge® 

EB401421 

CHECKING THE TIMING CHAIN, 
CAMSHAFT SPFROCKETS, AND TIMING 
CHAIN GUIDES 

The following procedure applies to all of the 
camshaft sprockets and timing chain guides. 

1. Check: 

• timing chain © 

Damage/stiffness -► Replace the timing 
chain and camshaft sprockets as a set. 

2. Check: 

• camshaft sprocket 

More than 1 I A tooth ® wear -► Replace 
the camshaft sprockets and the timing 
chain as a set. 

® 1 1 A tooth 

© Correct 

© Timing chain roller 

(2) Camshaft sprocket 

3. Check: 

• timing chain guide (exhaust side) 

• timing chain guide (intake side) 

• timing chain guide (top side) 
Damage/wear -► Replace the defective 
part(-s). 



4-10 



CAMSHAFT 





EB401430 

CHECKING THE TIMING CHAIN TENSIONER 

1. Check: 

• timing chain tensioner 
Cracks/damage -+ Replace. 

2. Check: 

• one-way cam operation 

Rough movement — ► Replace the timing 
chain tensioner housing. 

3. Check: 

• cap bolt ® 

• copper washer (2) 

• ball ® 

• spring @ 

• ball © 

• one-way cam (6) 

• gasket 

• timing chain tensioner rod (7) 
Damage/wear -► Replace the defective 
part(-s). 



EB401702 

INSTALLING THE CAMSHAFTS 

1. Install: 

• exhaust camshaft ® 

• intake camshaft @ 

(with the camshaft sprockets temporarily 
tightened) 

NOTE: 

Install the camshafts with their punch marks 
facing up. 



2. Install: 

• dowel pins ® 

• intake camshaft caps (§) 

• exhaust camshaft caps ® 

NOTE: 

Install the camshaft cap with the arrow mark 
(D pointing towards the right side of the en- 
gine. 



3. Install: 
• camshaft cap bolts 

NOTE: 



Tighten the camshaft cap bolts in stages 
and in a crisscross pattern, working from 
the inner caps out. 

Do not install the designated camshaft cap 
bolts ® at this stage. 



4-11 



CAMSHAFT 




CAUTION: 

The camshaft cap bolts must be tight- 
ened evenly or damage to the cylinder 
head, camshaft caps, and camshafts will 
result. 



Camshaft cap bolt 
10Nm(1.0iTTkg) 




4. Install: 

• intake camshaft sprocket 

• exhaust camshaft sprocket 



a. Turn the crankshaft counterclockwise. 

b. When piston #1 is at TDC on the com- 
pression stroke, align the "T" mark (a) on 
the magneto rotor with the stationary 
pointer ® on the crankcase. 

c. Install the timing chain onto both cam- 
shaft sprockets and then install the cam- 
shaft sprockets onto the camshafts. 

NOTE: 

• When installing the camshaft sprockets, 
start with the exhaust camshaft and be 
sure to keep the timing chain as tight as 
possible on the exhaust side. 

• Make sure that the match marks © are 
parallel with the edge of the cylinder head. 

"I": Intake side 
"E": Exhaust side 

CAUTION: 



Do not turn the crankshaft when instal- 
ling the camshaft to avoid damage or im- 
proper valve timing. 

d. After the crankshaft is turned several full 
turns and piston #1 is at TDC, make sure 
that marks ® and © are aligned. 




5. Install: 

• timing chain guide (exhaust side) 

6. Install: 

• timing chain tensioner 

a. Remove the cap bolt ® , washer (2), and 
springs ® 

b. Release the timing chain tensioner one- 
way cam ® and push the timing chain 
tensioner rod (5) all the way into the timing 
chain tensioner housing. 

c. Install the timing chain tensioner and gas- 
ket @ onto the cylinder block. 



4-12 



CAMSHAFT 






A WARNING 



Always use a new gasket. 



X 



Timing chain tensioner bolt 
10Nm(1.0nvkg) 



d. Install the springs ®, washer©, and cap 
bolt©. 



V 



Cap bolt 
20 Nm (2.0 irrkg) 



7. Turn: 

• crankshaft 

(several full turns counterclockwise) 

8. Check: 

• "T" mark ® 

Make sure that the "T" mark on the magne- 
to rotor is aligned with the stationary point- 
er © on the crankcase. 

• camshaft punch marks © 

Make sure that the punch marks on the 

camshafts are aligned with the embossed 

marks @ on the camshaft cap. 

Out of alignment -► Adjust. 

Refer to the installation steps above. 

9. Tighten: 

• camshaft sprocket bolts 

CAUTION: 



Be sure to tighten the camshaft sprocket 
bolts to the specified torque to avoid the 
possiblity of the bolts coming loose and 
damaging the engine. 



X 



Camshaft sprocket bolt 
24 Nm (2.4 nrkg) 



10 



Measure: 

• valve clearance 
Out of specification -»- Adjust. 
Refer to "ADJUSTING THE 
CLEARANCE" in chapter 3. 



VALVE 



4-13 



CYLINDER HEAD 




CYLINDER HEAD 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the cylinder head 




Remove the parts in the order listed. 




Camshaft 




Refer to "CAMSHAFT'section. 


1 


Union bolt 


2 




2 


Copper washer 


4 




3 


Oil delivery pipe 


1 




4 


Cylinder head 


1 " 


1 Refer to "REMOVING/INSTALLING THE 


5 


Cylinder head gasket 


1 - 


J CYLINDER HEAD" section. 


6 


Dowel pin 


2 


For installation, reverse the removal 
procedure. 



4-14 



CYLINDER HEAD 












^R^Lfjj^R^ 




REMOVING THE CYLINDER HEADS 

1. Remove: 
• cylinder head nuts 

NOTE: 



• Loosen the nuts in the proper sequence as 
shown. 

• Loosen each nut 1 12 of a turn at a time. 
After all of the nuts are fully loosened, re- 
move them. 



EB402403 

CHECKING THE CYLINDER HEADS 

The following procedure applies to all of the cyl- 
inder heads. 

1. Eliminate: 

• carbon deposits 

(from the combustion chambers with a 
pounded scraper) 

NOTE: 

Do not use a sharp instument to avoid dam- 
aging or scratching: 

• spark plug threads 

• valve seats 

2. Check: 

• cylinder head 
Damage/scratches -+ Replace. 

• cylinder head water jacket 
Mineral deposits/rust -► Eliminate. 

3. Measure: 

• cylinder head warpage 

Out of specification -► Resurface the cylin- 
der head. 




Cylinder head warpage 
Less than 0.05 mm 



a. Place a straightedge ® and a thickness 
gauge @ across the cylinder head. 

b. Measure the warpage. 

c. If the limited is exceeded, resurface the 
cylinder head as follows. 

d. Place a 400 ~ 600 grit wet sandpaper on 
the surface plate and resurface the cylin- 
der head using a figure-eight sanding pat- 
tern. 

NOTE: 

To ensure an even surface, rotate the cylin- 
der head several times. 



4-15 



CYLINDER HEAD 





■vm&s^jf^m? 



EB402702 

INSTALLING THE CYLINDER HEAD 

1. Install: 

• gasket (New) ® 

• dowel pins @ 

NOTE: 



The "UP" mark ® on the gasket must face 
up. 



2. Install: 

• cylinder head 

NOTE: 

• Apply engine oil onto the threads of the cyl- 
inder head nuts. 

• Tighten the cylinder head nuts in the prop- 
er tightening sequence as shown and 
torque them in two stages. 



Cylinder head nut 
First 20 Nm (2.0 nrkg) 
Second 35 Nm (3,5 nrkg) 



3. Install: 

• exhaust camshaft 

• intake camshaft 

Refer to "INSTALLING THE CAM- 
SHAFTS". 



4-16 



VALVES AND VALVE SPRINGS 



VALVES AND VALVE SPRINGS 





Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the valves and valve 




Remove the parts in the order listed. 




springs 








Camshaft 




Refer to "CAMSHAFT" section. 




Cylinder head 




Refer to "CYLINDER HEAD" section. 


1 


Valve lifter 


4 - 




2 


Adjusting pad 


4 




3 


Valve cotters 


8 




4 


Upper spring seat 


4 


Refer to "REMOVING/INSTALLING THE 


5 


Valve spring 


4 


VALVES" section. 


6 


Valve (intake) 


2 




7 


Valve (exhaust) 


2 




8 


Oil seal 


4 




9 


Lower spring seat 


4 - 


For installation, reverse the removal 
procedure. 



4-17 



VALVES AND VALVE SPRINGS 





EB403100 

REMOVING THE VALVES 

The following procedure applies to all of the 
valves and related components. 

NOTE: 

Before removing the internal parts of the 
cylinder head (e.g., valves, valve springs, 
valve seats), make sure that the valves 
properly seal. 

1. Remove: 

• valve lifter ® 

• valve pad 

NOTE: 

Make a note of the position of each valve 
lifter and valve pad so that they can be 
reinstalled in their original place. 

2. Check: 

• valve sealing 

Leakage at the valve seat -► Check the 

valve face, valve seat, and valve seat 

aidth. 

Refer to "CHECKING THE VALVE 

SEATS". 

a. Pour a clean solvent ® into the intake 
and exhaust ports. 

b. Check that the valves properly seal. 
There should be no leakage at the valve 
seat®. 









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3. Remove: 
• valve cotters ® 

NOTE: 



Remove the valve cotters by compressing 
the valve spring with the valve spring com- 
pressor (2) and attachment (3). 



y- 



Valve spring compressor 

90890-04019 
Attachment 

90890-04114 



, Remove: 

• upper spring seat ® 

• valve spring ® 

• oil seal ® 

• lower spring seat ® 

• valve (§) 

NOTE: 



Identify the position of each part very care- 
fully so that it can be reinstalled in its original 
place. 



4-18 



VALVES AND VALVE SPRINGS 





EB403400 

CHECKING THE VALVES AND VALVE 
GUIDES 

The following procedure applies to all of the 
valves and valve guides. 

1. Measure: 
• valve-stem-to-valve-guide clearance 



Valve-stem-to-valve-guide 
clearance = 

Valve guide inside diameter (a) - 

Valve stem diameter® 



Out of specification 
guide. 



Replace the valve 




Valve-stem-to-valve-guide 
clearance 
Intake 

Limit: 0.08 mm 
Exhaust 
Limit: 0.1 mm 



2. Replace: 
• valve guide 

NOTE: 



To ease valve guide removal and installa- 
tion, and to maintain the correct fit, heat the 
cylinder head to 100°C (212°C) in an oven. 




a. Remove the valve guide with a valve 
guide remover®. 

b. Install the new valve guide with a valve 
guide installer© and valve guide remov- 
er®. 

c. After installing the valve guide, bore the 
valve guide with a valve guide reamer (3) 
to obtain the proper valve-stem-to-valve- 
guide clearance. 

NOTE: 

After replacing the valve guide, reface the 
valve seat. 




Valve guide remover (o4.0 mm) 

90890-04111 
Valve guide installer (o4.0 mm) 

90890-04112 
Valve guide reamer (o4.0 mm) 

90890-04113 



3. Eliminate: 
• carbon deposits 
(from the valve face and valve seat) 



4-19 



VALVES AND VALVE SPRINGS 






eg- 



///////// //////// ////// 




4. Check: 

• valve face 

Pitting/wear -+ Grind the valve face. 

• valve stem end 

Mushroom shape of diameter larger than 
the body of the valve stem -► Replace the 
valve. 



5. Measure: 
• valve margin thickness ® 
Out of specification -► Replace the valve. 




Valve margin thickness 
0,5 mm 



6. Measure: 
• valve stem runout ® 
Out of specification -+ Replace the valve. 

When installing a new valve, always re- 
place the valve guide. 

If the valve is removed or replaced, always 
replace the oil seal. 




Valve stem runout 
Limit 0.04 mm 



EB403410 

CHECKING THE VALVE SEATS 

The following procedure applies to all of the 
valves and vlve seats. 

1. Eliminate: 

• carbon deposits 

(from the valve face and valve seat) 

2. Check: 

• valve seat 

Pitting/wear -+ Replace the cylinder head. 

3. Measure: 

• valve seat width (a) 

Out of specification -► Replace the cylin- 
der head. 




Valve seat width 
Intake: 0.9 ~ 1.1 mm 

(Limit 1.6 mm) 
Exhaust:0.9 ~ 1.1 mm 

(Limit 1.6 mm) 



4-20 



VALVES AND VALVE SPRINGS 





(6) 

^^^&^Z^ n 171601 



ENG 



^1 



a. Apply Mechanic's blueing dye (Dykem) 
® onto the valve face. 

b. Install the valve into the cylinder head. 

c. Press the valve through the valve guide 
and onto the valve seat to make a clear 
pattern. 

d. Measure the valve seat width. Where the 
valve seat and valve face contacted one 
another, the blueing will have been re- 
moved. 



Lap: 

• valve face 

• valve seat 

NOTE: 



After replacing the cylinder head or replac- 
ing the valve and valve guide, the valve seat 
and valve face should be lapped. 



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11171601 



a. Apply a coarse lapping compound (§) to 
the valve face. 

CAUTION: 

Do not let the lapping compound enter 
the gap between the valve stem and the 
valve guide. 

b. Apply molybdenum disulfide oil onto the 
valve stem. 

c. Install the valve into the cylinder head. 

d. Turn the valve until the valve face and 
valve seat are evenly polished, then 
clean off all of the lapping compound. 

NOTE: 



For the best lapping results, lightly tap the 
valve seat while rotating the valve back and 
forth between your hand. 

e. Apply a fine lapping compound to the 
valve face and repeat the above steps. 

f. After every lapping procedure, be sure to 
clean off all of the lapping compound from 
the valve face and valve seat. 

g. Apply Mechanic's blueing dye (Dykem) 
© onto the valve face. 

h. Install the valve into the cylinder head, 
i. Press the valve through the valve guide 

and onto the valve seat to make a clear 

impression, 
j. Measure the valve seat width (a) again. If 

the valve seat width is out of specification, 

reface and lap the valve seat. 



4-21 



VALVES AND VALVE SPRINGS 






EB403420 

CHECKING THE VALVE SPRINGS 

The following procedure applies to all of the 
valve springs. 

1. Measure: 
• valve spring free length ® 
Out of specification -► Replace the valve 
spring. 




Valve spring free length 
(intake and exhaust) 
Spring 
40.09 mm (Limit 37.5 mm) 



2. Measure: 
• compressed spring force (§) 

Out of specification -+ Replace the valve 

spring. 
© Installed length 




Compressed spring force 
Intake and exhaust spring 
13,4 ~ 15,6 kg at 34.5 mm 



3. Measure: 
• valve spring tilt ® 
Out of specification -► Replace the valve 
spring. 




Spring tilt limit 
Intake and exhaust spring 
1.8 mm 



EB403430 

CHECKING THE VALVE LIFTERS 

The following procedure applies to all of the 
valve lifters. 

1. Check: 
• valve lifter 
Damage/scratches -► Replace the valve 
lifters and cylinder head. 



4-22 



VALVES AND VALVE SPRINGS 





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EB403440 

CHECKING THE CAMSHAFT CAP 

1. Check: 

• camshaft case 

• camshaft caps ® 

Cracks/damage -+ Replace th camshaft 
case and camshaft caps as a set, and 
check the camshafts (Refer to "CHECK- 
ING THE CAMSHAFTS".). 

• camshaft bearing surfaces (2) 
Damage/pitting/scratches -► Replace the 
camshaft case and camshaft caps as a 
set, and check the camshafts (Refer to 
"CHECKING THE CAMSHAFTS".). 

2. Check: 

• oil delivery pipes ® 

Damage -► Replace the defective part(-s). 
Dirt/obstruction -+ Wash the pipe(-s) and 
then blow it out with compressed air. 



EB403700 

INSTALLING THE VALVES 

The following procedure applies to all of the 
valves and related components. 



1 



Deburr: 

• valve stem end 
(with an oil stone) 

Lubricate: 

• valve stem ® 

• oil seal 

(with the recommended lubricant) 



Recommended lubricant 
Molybdenum disulfide oil 



3. Install: 

• valve ® 

• lower spring seat (2) 

• oil seal ® 

• valve spring @ 

• upper spring seat © 
(into the cylinder head) 

NOTE: 



Install the valve spring with the larger pitch 
(D facing up. 

© Smaller pitch 

4. Install: 
• valve cotters ® 

NOTE: 

Install the valve cotters by compressing the 
valve spring with the valve spring compres- 
sor (D and attachment ® . 



4-23 



VALVES AND VALVE SPRINGS 




ENG 



m 



y- 



Valve spring compressor 

90890-04019 
Attachment 

90890-04114 



5. To secure the valve cotters (D onto the a 
valve stem, lightly tap the valve tip with a 
soft-face hammer. 

CAUTION: 



Hitting the valve tip with excessive force 
could damage the valve. 

.Install: 

• valve pad ® 

• valve lifter (2) 

NOTE: 

• Apply molybdenum disulfide oil onto the 
valve lifter and valve pad. 

• The valve lifter must move smoothly when 
rotated with a finger. 

• Each valve lifter and valve pad must be re- 
installed in its original position. 



4-24 



CYLINDER AND PISTON 



CYLINDER AND PISTON 





Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the cylinder and pistons 




Remove the parts in the order listed. 




Cylinder head 




Refer to "CYLINDER HEAD" section. 


1 


Water jacket joint 


1 




2 


O-ring 


2 




3 


Cylinder 


1 - 




4 


Cylinder gasket 


1 


Refer to "INSTALLING THE PISTON AND 


5 


Dowel pin 


2 


CYLINDER" section. 


6 


O-ring 


4 - 




7 
8 
9 
10 


Piston pin circlip 
Piston pin 
Piston 
Piston ring set 


8 - 
4 
4 
4 - 


Refer to "REMOVING THE CYLINDER 


AND PISTONS/INSTALLING THE 


. PISTON AND CYLINDER" section. 








For installation, reverse the removal 








procedure. 



4-25 



CYLINDER AND PISTON 







UJ 11221001 




REMOVING THE CYLINDERS AND PISTONS 

The following procedure applies to all of the cyl- 
inders and pistons. 
1. Remove: 

• piston pin clip® 

• piston pin (2) 

• piston (3) 

CAUTION: 



Do not use a hammer to drive the piston 
pin out. 

NOTE: 

• Before removing the piston pin clip, cover 
the crankcase opening with a clean rag to 
prevent the piston pin clip from falling into 
the crankcase. 

• For reference during installation, put an 
identification mark on each piston crown. 

• Before removing the piston pin, deburr the 
piston pin clip's groove and the piston's pin 
bore area. If both areas are deburred and 
the piston pin is still difficult to remove, re- 
move it with the piston pin puller @. 



y- 



Piston pin puller 
90890-01304 



2. Remove: 

• top ring 

• 2nd ring 

• oil ring 

NOTE: _ 



When removing a piston ring, open the end 
gap with your fingers and lift the other side of 
the ring over the piston crown. 





( 1 




t 


i 






i 










L J 


11210101 



EB404405 

CHECKING THE CYLINDERS AND PISTONS 

The following procedure applies to all of the cyl- 
inders and pistons. 

1. Check: 

• piston wall 

• cylinder wall 

Vertical scratches -► Rebore or replace 
the cylinder, and replace the piston and 
piston rings as a set. 

2. Measure: 

• piston-to-cylinder clearance 

a. Measure cylinder bore "C" with the cylin- 
der bore gauge. 
© 20 mm from the top of the cylinder 

NOTE: 

Measure cylinder bore "C" by taking side-to- 
side and front-to-back measurements of the 
cylinder. Then, find the average of the mea- 
surements. 



4-26 



CYLINDER AND PISTON 







Standard 


Wear limit 


Cylinder 
bore "C" 


62.00 ~ 62.01 


62.1 mm 


fitfNjj X + Y 
C " 2 



b. If out of specification, replace the cylin- 
der, piston and piston rings as a set. 

c. Measure piston skirt diameter "P" with the 
micrometer. 

(a) 5 mm from the bottom edge of the piston. 





Piston size P 


Standard 


61.960 ~ 61.975 



d. If out of specification, replace the piston 
and piston rings as a set. 

e. Calculate the piston-to-cylinder clear- 
ance with the following formula. 



Piston-to- cylinder bore "C" - 

cylinder Piston skirt 

clearance diameter "P" 




Piston-to-cylinder clearance 
0.025 ~ 0.050 mm 
<Limit>: 0.07 mm 



f. If out of specification, replace the cylin- 
der, piston and piston rings as a set. 







v^® 


/ \y 


j^-vF 


\\ 



EB404410 

CHECKING THE PISTON RINGS 

1. Measure: 
• piston ring side clearance ® 
Out of specification -+ Replace the piston 
and piston rings as a set. 

NOTE: 

Before measuring the piston ring side clear- 
ance, eliminate any carbon deposits from 
the piston ring grooves and piston rings. 




Piston ring side clearance 
Top ring 

0.020 ~ 0.075 mm 

<Limit>: 0.1 mm 
2nd ring 

0.020 ~ 0.055 mm 

<Limit>: 0.1 mm 



4-27 



CYLINDER AND PISTON 





2. Install: 
• piston ring ® 
(into the cylinder) 

NOTE: 



Level the piston ring in the cylinder with the 
piston crown as shown. 



® 20 mm 

3. Measure: 
• piston ring end gap 
Out of specification 
ring. 

NOTE: 



Replace the piston 



The oil ring expander spacer's end gap can- 
not be measured. If the oil ring rail's gap is 
excessive, replace all three piston rings. 




Piston ring end gap 

Top ring 
0.15 ~ 0.30 mm 
<Limit>: 0.6 mm 

2nd ring 
0.25 ~ 0.40 mm 
<Limit>: 0.7 mm 

Oil ring 
0.1 ~ 0.35 mm 



EB404421 

CHECKING THE PISTON PINS 

The following procedure applies to all of the pis- 
ton pins. 
1. Check: 
• piston pin 
Blue discoloration/grooves -► Replace the 
piston pin and then check the lubrication 
system. 




2. Measure: 
• piston pin outside diameter (a) 
Out of specification -+ Replace the piston 
pin. 




Piston pin outside diameter 
16.991 ~ 17.000 mm 



4-28 



CYLINDER AND PISTON 





3. Calculate: 
• piston-pin-to-piston clearance 
Out of specification -► Replace the piston 
pin. 




Piston-pin-to-piston clearance = 
Piston pin bore size ® - 
Piston pin outside diameter ® 

Piston-pin-to-piston clearance 
0.011 ~ 0.013 mm 
<Limit>: 0.023 mm 



EB404701 

INSTALLING THE PISTON AND CYLINDER 

The following procedure applies to all of the pis- 
tons and cylinders. 
1. Install: 

• top ring ® 

• 2nd ring (2) 

• lower oil ring rail (3) 

• upper oil ring rail ® 

• oil ring expander® 

NOTE: 

Be sure to install the piston rings so that the 
manufacturer's marks or numbers face up. 



2. Install: 

• piston ® 

• piston pin (2) 

• piston pin clip (New) (3) 

NOTE: 



• Apply engine oil onto the piston pin. 

• Make sure that the "EX" mark® on the pis- 
ton faces towards the exhaust side of the 
engine. 

• Before installing the piston pin clip, cover 
the crankcase opening with a clean rag to 
prevent the clip from falling into the crank- 
case. 

3. Install: 

• gasket (New) ® 

• dowel pins (g) 

4. Lubricate: 

• piston 

• piston rings 

• cylinder 

(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



4-29 



CYLINDER AND PISTON 




® 


© 


©1 


-V s © 

© 




.Offset: 
• piston ring end gaps 

(a) Top ring 

(b) Lower oil ring rail 
© Upper oil ring rail 

(d) 2nd ringe 

(e) Oil ring expander 



6. Install: 

• cylinder® 

• O-ring ® 

NOTE: 



• First, install pistons #2 and #3. 

• Pass the timing chain and timing chain 
guide (exhaust side) through the timing 
chain cavity. 

a. Install a piston ring compressor ® to pis- 
ton #2 and #3. 

b. Install pistons #2 and #3 onto the cylinder. 

c. Remove the piston ring compressor. 

d. Install the piston ring compressor ® to 
pistons #1 and #4. 

e. Install pistons #1 and #4 onto the cylinder. 

f. Remove the piston ring compressor. 




Piston ring compressor: 
90890-04044 



4-30 



CLUTCH 

CLUTCH COVER 



CLUTCH 





Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the clutch cover 




Remove the parts in the order listed. 




Drain the engine oil 




Refer to "CHANGING THE ENGINE OIL" 
section in chapter 3. 


1 


Clutch cover 


1 




2 


Clutch cover gasket 


1 




3 


Dowel pin 


2 




4 


Drive sprocket cover 


1 




5 


Clutch cable 


1 


For installation, reverse the removal 
procedure. 



4-31 



CLUTCH 



CLUTCH 




70 Nm (7.0 nvkg) 



12 




8 Nm (0.8 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the clutch 




Remove the parts in the order listed. 


1 


Compression spring 


6 - 




2 


Pressure plate 


1 




3 


Short clutch push rod 


1 




4 


O-ring 


1 




5 


Ball 


1 




6 


Long clutch push rod 


1 


Refer to "INSTALLING THE CLUTCH" 


7 


Friction plate 


8 


section. 


8 


Clutch plate 


8 




9 


Fricition plate (large) 


1 




10 


Clutch spring plate 


1 - 




11 


Nut 


1 


Refer to "REMOVING/INSTALLING THE 
CLUTCH" section. 



4-32 



CLUTCH 





8 Nm (0.8 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


12 


Lock washer 




-i Refer to "REMOVING/INSTALLING 


13 


Clutch boss 


J THE CLUTCH" section. 


14 


Thrust washer 




Refer to "INSTALLING THE CLUTCH" 
section. 


15 


Spacer 




-. Refer to "REMOVING/ INSTALLING 


16 


Bearing 


J THE CLUTCH" section. 


17 
18 
19 


Clutch housing 
Thrust washer 
Spacer 




" Refer to "INSTALLING THE CLUTCH" 
seciton. 

For installation, reverse the removal 
procedure. 



4-33 



CLUTCH 















, 1 ■ ' ■ 1 I J | | i | , | , | , |\ 










311 000 







\ \N 






\ r^ 








/ "^ £Zr^K 


^^S. ' 








\ ^\ X 


\ 


>v s\k 




\ \ 




\ A ^tJ 










® 




311-002 



EB405100 

REMOVING THE CLUTCH 

1 . Straighten the lock washer tab. 

2. Loosen: 

• clutch boss nut® 

NOTE: 



While holding the clutch boss® with the uni- 
versal clutch holder (3), loosen the clutch 
boss nut. 



y- 



Universal clutch holder < 
90890-04086 



3. Remove: 

• spacer ® 

• bearing (2) 

NOTE: 



Insert two M6-mm bolts (3) into the spacer 
and then remove the spacer by pulling on the 
bolts. 

EB405400 

CHECKING THE FRICTION PLATES 

The following procedure applies to all of the fric- 
tion plates. 

1. Check: 

• friction plate 

Damage/wear -► Replace the friction 
plates as a set. 

2. Measure: 

• friction plate thickness 

Out of specification -► Replace the friction 
plates as a set. 

NOTE: 

Measure the friction plate at four places. 




Friction plate thickness 

2.94 ~ 3.06 mm 
<Limit>: 2.8 mm 



EB405410 

CHECKING THE CLUTCH PLATES 

The following procedure applies to all of the 
clutch plates. 

1. Check: 

• clutch plate 

Damage -+ Replace the clutch plates as a 
set. 

2. Measure: 

• clutch plate warpage 

(with a surface plate and thickness gauge 

©) 

Out of specification -+ Replace the clutch 
plates as a set. 




Clutch plate warpage limit 
Less than 0.1 mm 



4-34 




CLUTCH 




EB405420 

CHECKING THE CLUTCH SPRINGS 

The following procedure applies to all of the 
clutch springs. 

1. Check: " 

• clutch spring 

Damage -+ Replace the clutch springs as 
a set. 

2. Measure: 

• clutch spring free length (a) 

Out of specification -+ Replace the clutch 
springs as a set. 




Clutch spring free length 
34.9 mm 
<Limit>: 34.3 mm 



EB405430 

CHECKING THE CLUTCH SPRING PLATE 

1. Check: 

• clutch spring plate 
Damage -► Replace. 

2. Check: 

• clutch spring plate seat 
Damage -+ Replace. 




EB405440 

CHECKING THE CLUTCH HOUSING 

1. Check: 
• clutch housing dogs ® 
Damage/pitting/wear -+ Deburr the clutch 
housing dogs or replace the clutch hous- 
ing. 

NOTE: 

Pitting on the clutch housing dogs will cause 
erratic clutch operation. 



2. Check: 
• bearing (2) 
Damage/wear 
housing. 



Replace the clutch 



4-35 

















c 


A \ % 


i 


^^ 


1 ® 











CLUTCH 




EB405450 

CHECKING THE CLUTCH BOSS 

1. Check: 
• clutch boss splines ® 
Damage/pitting/wear -+ Replace the 
clutch boss. 

NOTE: 

Pitting on the clutch boss splines will cause 
erratic clutch operation. 




EB405450 

CHECKING THE PRESSURE PLATE 

1. Check: 

• pressure plate ® 
Cracks/damage -► Replace. 

• bearing @ 
Damage/wear -+ Replace. 



EB405480 

CHECKING THE CLUTCH PUSH RODS 

1. Check: 

• O-ring ® 

• short clutch push rod (§) 

• long clutch push rod ® 

• ball ® 
Cracks/damage/wear 
fective part(-s). 



Replace the de- 




2. Measure: 
• long clutch push rod bending limit® 
Out of specification -► Replace the long 
clutch push rod. 




Long clutch push rod bending 
limit 
0.3 mm 




EB405701 

INSTALLING THE CLUTCH 

1. Install: 

• bearing © 

• spacer © 

NOTE: 



Install the spacer with the two screw holes 
facing towards the clutch boss. 



4-36 





5) ^GD 



<c =^ 







CLUTCH 




2. Tighten: 
• clutch boss nut ® RT 



70 Nm (7.0 nrkg) 



NOTE: 

While holding the clutch boss with the uni- 
versal clutch holder (2), tighten the clutch 
boss nut. 




Universal clutch holder 
90890-04086 



3. Bend the lock washer ® tab along a flat side 
of the nut. 

4. Lubricate: 

• long clutch push rod ® 

• ball ® 

• short clutch push rod (3) 

• O-ring (3) 

(with the recommended lubricant) 



Recommended lubricant 
Lithium soap base grease 



5. Install: 

• long clutch push rod 

• ball 

• short clutch push rod 
(along with a new O-ring ®) 

6. Lubricate: 

• friction plates ® 

• clutch plates (§) 

(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



7. Install: 

• friction plates ® 

• clutch plates © 



a. Install a friction plate and clutch plate. 

b. Install a clutch spring plate, friction plate 
(large of inside dia.) and clutch plate. 

c. Install a friction plate and then alternate 
between a clutch plate and a friction 
plate. 



8. Install: 

• pressure plate ® 

• clutch springs (§) 

• clutch spring bolts ' 

NOTE: 



8.0 Nm (0.8 rrvkg) 



When installing the clutch springs, alter- 
nate between long and short clutch 
springs. 

Tighten the clutch spring bolts in stages 
and in a crisscross pattern. 



4-37 



CLUTCH 





9. Install: 
• clutch cover © {\ 



12Nm(1.2nvkg) 



NOTE: 

Tighten the clutch cover bolts in stages and 
in a crisscross pattern. 



4-38 



SHIFT SHAFT 



SHIFT SHAFT 





Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the shift shaft 




Remove the parts in the order listed. 




Oil pump 




Refer to "OIL PUMP" section. 




Drive sprocket cover 




Refer to "REMOVING THE ENGINE" 
section. 


1 


Collar 






2 


Shift shaft 






3 


Shift lever spring 




Refer to "INSTALLING THE SHIFT 


4 


Stopper lever 




SHAFT" section. 


5 


SHift lever spring 




For installation, reverse the removal 
procedure. 



4-39 



SHIFT SHAFT 





EB408400 

CHECKING THE SHIFT SHAFT 

1. Check: 

• shift shaft® 

• shift lever® 
Bends/damage/wear -► Replace. 

• shift lever spring (3) 

• stopper lever spring ® 
Damage/wear -► Replace. 



EB408700 

INSTALLING THE SHIFT SHAFT 

1. Install: 

• stopper lever ® 

• stopper lever spring (2) 

• shift shaft lever 

NOTE: 



Hook the ends of the stopper lever spring 

onto the stopper lever and the crankcase 

boss. 

Mesh the stopper lever with the shift drum 

segment assembly. 



2. Install: 
• shift shaft® 

NOTE: 



Lubricate the oil seal lips with lithium soap 
base grease. 

Hook the end of the shift lever spring onto 
the shift lever spring stopper (2). 



4-40 



AC MAGNETO AND STARTER CLUTCH 




AC MAGNETO AND STARTER CLUTCH 

STATOR COIL 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the stator coil 

Seat 




Remove the parts in the order listed. 
I Refer to "FRONT COWLING/SEAT/ 




Fuel tank 




J SIDE COVER/FUEL TANK" section in 


1 
2 


Stator/pickup coil lead 
Cover 


1/1 
1 


chapter 3. 


3 


Generator cover 


1 




4 
5 


Dowel pin 
Stator coil 


2 

1 


For installation, reverse the removal 
procedure. 



4-41 



AC MAGNETO AND STARTER CLUTCH 



STARTER CLUTCH 





80 Nm (8.0 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the starter clutch 




Remove the parts in the order listed. 




Generator cover 






1 


Starter clutch cover 


1 




2 


Dowel pin 


2 




3 


Gasket 






4 


Starter clutch assembly 




Refer to "REMOVING/INSTALLING THE 
STARTER CLUTCH" section. 


5 


Wood ruff key 






6 


Starter wheel gear 






7 


Shaft (Primary) 






8 


Starter idle gear (primary) 






9 


Shaft (Secondary) 






10 


Starter idle gear (secondary) 






11 


Shaft drive gear 




For installation, reverse the removal 
procedure. 



4-42 



AC MAGNETO AND STARTER CLUTCH 




AC MAGNETO ROTOR 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the generator roter 




Remove the parts in the order listed. 


1 


Bolt/washer 


1/1- 


-i Refer to "REMOVING/INSTALLING 


2 


Rotor 


1 


THE AC MAGNETO" section. 


3 


Woodruff key 


1 - 


For installation, reverse the removal 
procedure. 



4-43 



AC MAGNETO AND STARTER CLUTCH 





EB410100 

REMOVING THE STARTER CLUTCH 

1. Remove: 
• starter clutch cover ® 

NOTE: 



Loosen each bolt 1 /4 of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them. 



2. Remove: 
• starter clutch bolt ® 



NOTE: 

• While holding the magneto rotor (2) with 
the sheave holder ® , remove the starter 
clutch bolt. 




Sheave holder 
90890-01701 



3. Remove: 
• starter clutch ® 
(with the flywheel puller set (§)) 




Flywheel puller set 
90890-01362 



REMOVING THE AC MAGNETO 

1. Remove: 

• Bolt (AC magneto rotor) ® 

• Washer 

NOTE: 



While holding the AC magneto rotor© with a 
sheave holder (3), loosen the AC magneto 
rotor bolt®. 




Sheave holder: 
90890-01701 



4-44 



AC MAGNETO AND STARTER CLUTCH 



2. Remove: 

• AC magneto rotor ® 

• Woodruff key 

NOTE: 





Use a flywheel puller © to remove the AC 
magneto rotor®. 




Flywheel puller: 
90890-01362 




CHECKING THE STARTER CLUTCH 

1. Check: 

• starter clutch idle gear ® 

• starter clutch drive gear (2) 

• starter clutch gear (3) 
Burrs/chips/roughness/wear -+ Replace 
the defective part(-s). 





2. Check: 
• starter clutch operation 



a. When turning the starter clutch drive gear 
clockwise @, the starter clutch and the 
starter clutch drive gear should engage. 
If the starter clutch drive gear and starter 
clutch do not engage, the starter clutch is 
faulty and must be replaced. 

b. When turning the starter clutch drive gear 
counterclockwise ® , it should turn freely. 
If the starter clutch drive gear does not 
turn freely, the starter clutch is faulty and 
must be replaced. 



4-45 



AC MAGNETO AND STARTER CLUTCH 





INSTALLING THE AC MAGNETO 

1. Install: 

• Woodruff key ® 

• AC magneto rotor @ 

• Bolt (AC magneto rotor) 

NOTE: 



• Clean the tapered portion of the crankshaft 
and the AC magneto rotor. 

• When installing the AC magneto rotor, 
make sure that the woodruff key is properly 
seated in the key way of the crankshaft. 

2. Tighten: 

• Bolt (magneto rotor) 



Bolt (AC magneto rotor): 
130 Nm (13.0 irrkg) 



NOTE: 

While holding the AC magneto rotor® with a 
sheave holder® tighten the AC magneto ro- 
tor bolt ®. 




Sheave holder: 
90890-01701 




EB410710 

INSTALLING THE STARTER CLUTCH 

1. Install: 

• starter clutch ® 

NOTE: 

• While holding the generator rotor ® with 
the sheave holder ©, tighten the starter 
clutch bolt. 




V 



Sheave holder 
90890-01701 



Starter clutch bolt 
80 Nm (8.0 rrvkg) 



4-46 



OIL PAN AND OIL STRAINER 



OIL PAN AND OIL STRAINER 

OIL STRAINER 




1 IflM 



10Nm(1.0m-kg) 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the oil strainer 




Remove the parts in the order listed. 




Engine 




Refer to "REMOVING THE ENGINE" 
section. 


1 


Oil level warning switch/O-ring 


1/1- 




2 


Oil pan 


1 


Refer to "INSTALLING THE OIL PAN" 


3 


Dowel pin 


2 


section. 


4 


Oil pan gasket 


1 - 




5 


Relief valve/O-ring 


1/1 




6 


Oil strainer 


1 - 
1 - 


1 Refer to "INSTALLING THE OIL 


7 


Oil strainer housing 


J STRAINER" section. 


8 


Oil bypass valve 


1 




9 


Oil cooler/O-ring 


1/1 


Refer to "INSTALLING THE ADAPTOR" 

section. 

For installation, reverse the removal 

procedure. 



4-47 



OIL PUMP 



OIL PAN AND OIL STRAINER 





10Nm(1.0irvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the oil pump 




Remove the parts in the order listed. 




Clutch 




Refer to "CLUTCH" section. 


1 
2 
3 


Oil pump assembly 
Oil pump gasket 
Dowel pin 


1 - 
1 
1 - 


~ Refer to "INSTALLING THE OIL PUMP" 
section. 

For installation, reverse the removal 
procedure. 



4-48 



OIL PAN AND OIL STRAINER 





Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the oil pump 




Disassembly the parts in the order listed. 


© 


Oil pump rotor housing 


1 - 




® 


Dowel pin 


2 




(3) 


Inner rotor/outer rotor 


1/1 


Refer to "ASSEMBLING THE OIL PUMP" 


(3) 


Dowel pin 


1 


section. 


© 


Oil pump shaft assembly 


1 




© 


Oil pump cover 


1 - 




<Z) 


Washer 


1 


For assembly, reverse the disassembly 
procedure. 



4-49 



OIL PAN AND OIL STRAINER 





EB411100 

REMOVING THE OIL PAN 

1. Remove: 

• oil level switch ® 

• oil pan (D 

• gasket 

• dowel pins 

NOTE: 



Loosen each bolt 1 /4 of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them. 

EB411401 

CHECKING THE OIL PUMP 



1 



.Check: 

• oil pump drive gear® 

• oil pump driven gear (2) 

• oil pump housing® 

• oil pump housing cover® 
Cracks/damage/wear -► Replace the de- 
fective part(-s). 

. Measure: 

• inner-rotor-to-outer-rotor-tip clearance [A] 

• outer-rotor-to-oil-pump-housing clear- 
ance \3\ 

• oil-pump-housing-to-inner-rotor-and-out- 
er-rotor clearance El 

Out of specification -+ Replace the oil 

pump. 
© Inner rotor 
© Outer rotor 
© Oil pump housing 




Inner-rotor-to-outer-rotor-tip 
clearance 

0.03 ~ 0.09 mm Limit 0.15 mm 
Outer-rotor-to-oil-pump- 
housing clearance 

0.03 ~ 0.08 mm Limit 0.15 mm 
Oil-pump-housing-to-inner- 
rotor-and-outer-rotor clearance 

0.03 ~ 0.08 mm Limit 0.15 mm 



3. Check: 

• oil pump operation 

Unsmooth -► Repeat steps (1) and (2) or 
replace the defective part(-s). 

EB411410 

CHECKING THE RELIEF VALVE 

1. Check: 

• relief valve body ® 

• relief valve (§) 

• spring ® 

• O-ring (4) 

Damage/wear -► Replace the defective 
part(-s). 



4-50 



OIL PAN AND OIL STRAINER 





EB411430 

CHECKING THE OIL STRAINER 

1. Check: 
• oil strainer® 
Damage -► Replace. 
Contaminants — ► Clean with engine oil. 




EB411470 

CHECKING THE OIL NOZZLE 

1. Check: 

• oil nozzle® 

• check ball © 
Damage/wear 

• O-ring ® 
Damage/wear 



Replace the oil nozzle. 



Replace. 
• oil nozzle passage 
Obstruction — ► Blow out with compressed 
air. 




EB411701 

ASSEMBLING THE OIL PUMP 

1. Lubricate: 

• inner rotor 

• outer rotor 

• oil pump shaft 

(with the recommended lubricant) 



Recommended lubricant 
Engine oil 





Install: 

• oil pump shaft® 

(to the oil pump cover (§)) 

• washer 

• pin® 

• inner rotor® 

• outer rotor ® 

• dowel pin ® 

• oil pump housing® 

NOTE: 



7.0 Nm (0.7 nvkg) 



When installing the inner rotor, align the pin 
(D in the oil pump shaft with the groove ® on 
the inner rotor®. 

3. Check: 
• oil pump operation 
Refer to "CHECKING THE OIL PUMP". 



4-51 



OIL PAN AND OIL STRAINER 





EB411710 

INSTALLING THE OIL PUMP 

Install: 

•oil pump© [\ 



10Nm(1.0nvkg) 



CAUTION: 

After tightening the bolts, make sure that 
the oil pump turns smoothly. 

NOTE: 

Align the projection (a) on the oil pump shaft 
with the slot © on the water pump shaft. 

NOTE: 

Align the arrow © on the oil pump with the 
arrow © on the crankcase. 



EB411720 

INSTALLING THE OIL STRAINER 

1. Install: 
• oil strainer housin g ® 

LOCKTITE^ 



10Nm(10nvkg) 



NOTE: 

The arrow® on the oil strainer housing must 
point towards the front of the engine. 



2. Install: 
• oil strainer cover ® 

NOTE: 

The arrow @ on the oil strainer cover must 
point towards the rear of the engine. 



EB411730 

INSTALLING THE OIL PAN 

1. Install: 

• dowel pins 

• gasket (New) 

• oil pan ® 

• oil level switch (2) 

• engine oil drain bolt 



A WARNING 



Always use new copper washers. 



4-52 



OIL PAN AND OIL STRAINER 




NOTE: 

• Tighten the oil pan bolts in stages and in a 
crisscross pattern. 

• Lubricate the oil level switch's O-ring with 
engine oil. 



X 



Oil pan bolt 

12Nm(1.2irrkg) 
Oil level switch bolt 

7 Nm (0.7 rrrkg) 



4-53 



CRANKCASE 



CRANKCASE 




"^ 24 Nm (2.4 m-kg) 

(12) 



12Nm(1.2nrkg) 




10 Nm (1.0 m-kg) 



"^ 24 Nm (2.4 m-kg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the crankcase 




Disassembly the parts in the order listed. 




Engine 




Refer to "REMOVING THE ENGINE" 
section. 




Camshaft 




Refer to "CAMSHAFT" section. 




Cylinder head 




Refer to "CYLINDER HEAD" section. 




Cylinder, piston 




Refer to "CYLINDER AND PISTON" 
section. 




Clutch 




Refer to "CLUTCH" section in chapter 4. 




Oil pump 




Refer to "OIL PUMP" section. 




Shift shaft 




Refer to "SHIFT SHAFT" section. 




Magneto rotor 




1 Refer to "AC MAGNETO AND STARTER 
J CLUTCH section. 




Starter clutch 






Oil strainer 




Refer to "OIL PAN AND OIL STRAINER" 
section. 




Water pump 




Refer to "WATER PUMP" section in 
chapter 5. 


1 


Oil seal stopper plate 


1 




2 


Neutral switch lead 


1 




3 


Neutral switch 


1 





4-54 



CRANKCASE 




"^ 24 Nm (2.4 nvkg) 

02> 



12Nm(1.2nrkg) 




10Nm(1.0nrkg) 



^~ 24 Nm (2.4 nrkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


4 


O-ring 






5 


Upper crankcase 




Refer to "DISASSEMBLING/ 


6 


Dowel pin 




ASSEMBLING THE CRANKCASE" 


7 


Oil seal 




section. 


8 


Oil jet 






9 


O-ring 




For assembly, reverse the disassembly 
procedure. 



4-55 



CRANKCASE 




® 







© © 







EB412100 

DISASSEMBLING THE CRANKCASE 

1. Remove: 
• crankcase bolts ® ~ © 
O Upper crankcase 

NOTE: 



• Loosen each bolt 1 /4 of a turn at a time, in 
stages and in a crisscross pattern. After all 
of the bolts are fully loosened, remove 
them. 

• Loosen the bolts in decreasing numerical 
order (refer to the numbers in the illustra- 
tion). 

• The numbers embossed on the crankcase 
indicate the crankcase tightening se- 
quence. 

2. Place the engine upside down. 

3. Remove: 

• lower crankcase bolts ® ~ ® 
\B\ lower crankcase 

4. Remove: 

• lower crankcase 

CAUTION: 

Tap on one side of the crankcase with a 
soft-face hammer. Tap only on reinforced 
portions of the crankcase, not on the 
crankcase mating surfaces. Work slowly 
and carefully and make sure that the 
crankcase halves separate evenly. 

5. Remove: 

• dowel pins 

• oil jet 

6. Remove: 

• crankshaft journal lower bearing 
(from the lower crankcase) 

NOTE: 

Identify the position of each crankshaft jour- 
nal lower bearing so that it can be reinstalled 
in its original place. 



EB412420 

CHECKING THE CRANKCASE 

1 . Thoroughly wash the crankcase halves in a 
mild solvent. 

2. Thoroughly clean all the gasket surfaces 
and crankcase mating surfaces. 

3. Check: 

• crankcase 
Cracks/damage -► Replace. 

• oil delivery passages 

Obstruction — ► Blow out with compressed 
air. 



4-56 



CRANKCASE 




EB412742 

ASSEMBLING THE CRANKCASE 

1. Lubricate: 
• crankshaft journal bearings 
(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



2. Apply: 
• sealant 
(onto the crankcase mating surfaces) 




Yamaha bond No. 1215 
90890-85505 




NOTE: 

Do not allow any sealant to come into con- 
tact with the oil gallery or crankshaft journal 
bearings. Do not apply sealant to within 2 - 
3 mm of the crankshaft journal bearings. 

3. Install: 

• dowel pin 

4. Install: 

• crankshaft journal lower bearings ® 
(into the lower crankcase) 

NOTE: 

• Align the projections ® on the crankshaft 
journal lower bearings with the notches © 
in the crankcase. 

• Install each crankshaft journal lower bear- 
ing in its original place. 

5. Set the shift drum assembly and transmis- 
sion gears in the neutral position. 

6. Install: 

• upper crankcase ® 

(onto the lower crankcase (D) 

CAUTION: 

Before tightening the crankcase bolts, 
make sure that the transmission gears 
shift correctly when the shift drum as- 
sembly is turned by hand. 



4-57 



IS 







© © 







CRANKCASE 




7. Install: 

• upper crankcase bolts 

• lower crankcase bolts 

NOTE: 



• Lubricate the bolt threads with engine oil. 

• Tighten the bolts in increasing numerical 
order. 

• Install washers on bolts © ~ ©■ 

• Install the cable holder on bolt #35. 

[A] Upper crankcase 

[B] Lower crankcase 



X 



M8 bolt 

24 Nm (2.4 nrkg) 
M6 bolt 

12 Nm (1.2 nrkg) 



4-58 



CRANKSHAFT 




CRANKSHAFT 




Order 


Job name/Part name 


Q'ty 


Remarks 


1 
2 
3 


Removing the crankshaft 

Disassembly the crankcase 
Timing chain guide (intake side) 
Crankshaft assembly 
Oil seal 


1 - 

1 

1 


Remove the parts in the order listed. 
Refer to "CRANKCASE" section. 

Refer to "REMOVING/INSTALLING THE 
CRANKSHAFT ASSEMBLY" section. 


4 
5 


Timing chain 

Crankshaft journal bearing 


1 - 
12 


For installation, reverse the removal 
procedure. 



4-59 



CRANKSHAFT 




CONNECTING ROD 




Order 


Job name/Part name 


Q'ty 


Remarks 


1 


Removing the connecting rod 

Nut 


8 - 
8 - 


Remove the parts in the order listed. 
-i Refer to "INSTALLING THE 


2 


Connecting rod bolt 


J CONNECTING RODS" section. 


3 
4 
5 


Connecting rod 
Connecting rod cap 
Connecting rod big end bearing 


4 - 
4 
8 - 


" Refer to "REMOVING/INSTALLING 
THE CONNECTING RODS" section. 

For installation, reverse the removal 
procedure. 



4-60 





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CRANKSHAFT 




REMOVING THE CRANKSHAFT ASSEMBLY 

1. Remove: 

• crankshaft assembly ® 

• crankshaft journal upper bearing (2) 
(from the upper crankcase) 

• timing chain guide (intake side) 

NOTE: 

Identify the position of each crankshaft jour- 
nal upper bearing so that it can be reinstalled 
in its original place. 




REMOVING THE CONNECTING RODS 

1. Remove: 

• connecting rods ® 

• big end bearings (2) 

NOTE: 



Identify the position of each big end bearing 
so that it can be reinstalled in its original 
place. 



I ~ : " " " : "* 



CHECKING THE CRANKSHAFT AND 
CONNECTING RODS 

1. Measure: 
• crankshaft runout 
Out of specification -► Replace the crank- 
shaft. 




Crankshaft runout 
Less than 0.03 mm 



2. Check: 

• crankshaft journal surfaces 

• crankshaft pin surfaces 

• bearing surfaces 

Scratches/wear -► Replace the crank- 
shaft. 

3. Measure: 

• crankshaft-journal-to-crankshaft-journal- 
bearing clearance 

Out of specification -► Replace the crank- 
shaft journal bearings. 



4-61 



CRANKSHAFT 



ENG 



M 




Crankshaft-journal-to-crank- 
shaft-journal-bearing clearance 

0.025 ~ 0.043 mm 

Limit 0.08 mm 




CAUTION: 

Do not interchange the crankshaft jour- 
nal bearings. To obtain the correct crank- 
shaft journal-to-crankshaft-journal-bear- 
ing clearance and prevent engine 
damage, the crankshaft journal bearings 
must be installed in their original posi- 
tion. 

a. Clean the crankshaft journal bearings, 
crankshaft journals, and bearing portions 
of the crankcase. 

b. Place the upper crankcase upside down 
on a bench. 

c. Install the crankshaft journal upper bear- 
ings ® and the crankshaft into the upper 
crankcase. 

NOTE: 

Align the projections ® of the crankshaft 
journal upper bearings with the notches ® in 
the crankcase. 



d. Put a piece of Plastigauge d 
crankshaft journal. 

NOTE: 



on each 



Do not put the Plastigauge® over the oil hole 
in the crankshaft journal. 

e. Install the crankshaft journal lower bear- 
ings into the lower crankcase and as- 
semble the crankcase halves. 

NOTE: 

• Align the projections ® of the crankshaft 
journal lower bearings with the notches © 
in the crankcase. 

• Do not move the crankshaft until the clear- 
ance measurement has been completed. 



4-62 



H 



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-Q 



J1 



Wft 



EB 



J2 J3 J4 J5 



J6 



CRANKSHAFT 




f. Tighten the bolts to specification in the 
tightening sequence cast on the crank- 
case. 



V 



Crankcase bolt 
M8: 

24 Nm (2.4 irrkg) 
M6: 
12Nm(1.2irrkg) 



[A] Upper crankcase 
\B\ Lower crankcase 

NOTE: 



Lubricate the crankcase bolt threads (M8) 
and (M6) with engine oil. 



g. Remove the lower crankcase and the 
crankshaft journal lower bearings. 

h. Measure the compressed Plastigauge® 
width © on each crankshaft journal. 
If the clearance is out of specification, se- 
lect replacement crankshaft journal bear- 
ings. 



4. Select: 
• Crankshaft journal bearings (J1 

NOTE: 



J6) 



The numbers [3 stamped into the crank- 
shaft web and the numbers ® stamped 
into the lower crankcase are used to deter- 
mine the replacement crankshaft journal 
bearing sizes. 

"J1 — J6" refer to the bearings shown in 
the crankshaft illustration. 
If "J1 ~ J6" are the same, use the same 
size for all of the bearings. 



4-63 











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CRANKSHAFT 




For example, if the crankcase "J-|" and 
crankshaft web "J1 " numbers are "6" and "2" 
respectively, then the bearing size for "J1 " is: 



Bearing size for J1 : 

Ji (crankcase) -J1 (crankshaft web) + 

1=6-2 + 1=5 (yellow) 



CRANKSHAFT 
JOURNAL 
BEARING 
COLOR CODE® 


1 


2 


3 


4 


5 


6 




blue 


black 


brown 


green 


yellow 


pink 



5. Measure: 
• crankshaft-pin-to-big-end-bearing clear- 
ance 

Out of specification -► Replace the big end 
bearings. 




Crankshaft-pin-to-big-end- 
bearing clearance 

0.043 ~ 0.066 mm 

Limit 0.08 mm 



The following procedure applies to all of 
the connecting rods. 

CAUTION: 

Do not interchange the big end bearings 
and connecting rods. To obtain the cor- 
rect crankshaft-pin-to-big-end-bearing 
clearance and prevent engine damage, 
the big end bearings must be installed in 
their original positions. 

a. Clean the big end bearings, crankshaft 
pins, and bearing portions of the connect- 
ing rods. 

b. Install the big end upper bearing into the 
connecting rod and the big end lower 
bearing into the connecting rod cap. 

NOTE: 

Align the projections (§) on the big end bear- 
ings with the notches (6) in the connecting 
rod and connecting rod cap. 

c. Put a piece of Plastigauge® ® on the 
crankshaft pin. 



4-64 





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11630602 




CRANKSHAFT 




NOTE: 

• Do not move the connecting rod or crank- 
shaft until the clearance measurement has 
been completed. 

• Apply molybdenum disulfide grease onto 
the bolts, threads, and nut seats. 

• Make sure that the "Y" mark © on the con- 
necting rod faces towards the left side of 
the crankshaft. 

• Make sure that the characters @ on both 
the connecting rod and connecting rod cap 
are aligned. 

e. Tighten the connecting rod nuts. 



V 



Nut (connecting rod): 
15Nm(1.5irrkg, 11 fflb) + 
(turn the nut another 90°) 



Refer to "INSTALLING THE CONNECT- 
ING RODS". 

Remove the connecting rod and big end 
bearings. 

Refer to "REMOVING THE CONNECT- 
ING RODS". 

Measure the compressed Plastigauge® 
width (§) on the crankshaft pin. 
If the clearance is out of specification, se- 
lect replacement big end bearings. 




6. Select: 
• big end bearings (P-| 

NOTE: 



P 4 ) 



• The numbers [A] stamped into the crank- 
shaft web and the numbers ® on the con- 
necting rods are used to determine the re- 
placement big end bearing sizes. 

• "P1 " ~ "P4" refer to the bearings shown in 
the crankshaft illustration. 



J 


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4-65 




vl ^=^M — ® 



CRANKSHAFT 




For example, if the connecting rod "Pi" and 
the crankshaft web "P1" numbers are "4" 
and "1" respectively, then the bearing size 
for "P-," is: 



Bearing size for P^ 

P<i (connecting rod) - P1 (crankshaft- 

web) = 4-1 =3 (brown) 



BIG END 
BEARING 
COLOR CODE (2) 


1 


2 


3 


4 




blue 


black 


brown 


green 





EB412700 

INSTALLING THE CONNECTING RODS 

1 . Lubricate: 

• bolt threads 

• nut seats 

(with the recommended lubricant) 



Recommended lubricant 
Molybdenum disulfide grease 



, Lubricate: 

• crankshaft pins 

• big end bearings 

• connecting rod inner surface 
(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



Install: 

• big end bearings ® 

• connecting rods (§) 

• connecting rod caps ® 
(onto the crankshaft pins) 

NOTE: 



• Align the projections on the big end bear- 
ings with the notches in the connecting 
rods and connecting rod caps. 

• Be sure to reinstall each big end bearing in 
its original place. 

• Make sure that the "Y" marks ® on the 
connecting rods face towards the left side 
of the crankshaft. 

• Make sure that the characters on both the 
connecting rod and connecting rod cap are 
aligned. 



4-66 




CRANKSHAFT 




4. Align: 

• bolt heads ® 

(with the connecting rod caps) 

5. Tighten: 

• Nuts (connecting rod) 



V 



Nut (connecting rod): 
15Nm(1.5irrkg) + 
(turn the nut another 90°) 



a. Replace the connecting rod bolts and 
nuts with new ones. 



CAUTION: 

Tighten the connecting rod bolts using 
the plastic-region tightening angle meth- 
od. 
Always install new bolts and nuts. 




b. Clean the connecting rod bolts and nuts. 

c. Tighten the connecting rod nuts. 

d. Put a mark ® on the corner of the con- 
necting rod nut (2) and the connecting rod 



Tighten the nut further to reach the speci- 
fied angle (90°). 



A WARNING 



When the nut is tightened more than the 
specified angle, do not loosen the nut 
and then retighten it. 
Replace the bolt with a new one and per- 
form the procedure again. 

CAUTION: 



• Do not use a torque wrench to tighten 
the nut to the specified angle. 

• Tighten the nut until it is at the specified 
angles. 

NOTE: 

When using a hexagonal nut, note that the 
angle from one corner to another is 60°. 



4-67 



CRANKSHAFT 





EB412720 

INSTALLING THE CRANKSHAFT 

1. Install: 
• crankshaft journal upper bearings ® 
(into the upper crankcase) 

NOTE: 



• Align the projections (D on the crankshaft 
journal upper bearings with the notches ® 
in the crankcase. 

• Be sure to install each crankshaft journal 
upper bearing in its original place. 

2. Install: 

• timing chain® 

(onto the crankshaft sprocket) 

• crankshaft assembly @ 

NOTE: 

• Pass the timing chain through the timing 
chain cavity. 

• To prevent the timing chain from falling into 
the crankcase, fasten it with a wire. 



3. Install: 
• timing chain guide ® [\ 



10Nm(1.0m«kg) 



4-68 



TRANSMISSION 




TRANSMISSION 




Order 


Job name/Part name 


Q'ty 


Remarks 


1 
2 


Removing the transmission 

Disassembly the crankcase 
Main axle assembly 
Circlip 




Remove the parts in the order listed. 

Refer to "CRANKCASE" section. 
1 Refer to "INSTALLING THE 
J TRANSMISSION" section. 


3 
4 
5 
6 


Bearing 

Bearing 

Drive axle assembly 

Circlip 




n Refer to "INSTALLING THE 
J TRANSMISSION" section. 


7 


Nozzle 






8 
9 


Bearing 
Plate washer 






10 


Oil seal/collar 


1/1 




11 


Bearing 




For installation, reverse the removal 
procedure. 



4-69 



TRANSMISSION 





Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the transmission 




Disassembly the parts in the order listed. 


® 


1st wheel gear 






@ 


5th wheel gear 






(3) 


Circlip 






® 


Washer 






® 


4th wheel gear 






® 


3rd wheel gear 






® 


6th wheel gear 






® 


2nd wheel gear 






® 


Washer 






© 


Circlip 






© 


Drive axle 






© 


2nd pinion gear 






© 


6th pinion gear 







4-70 



TRANSMISSION 





Order 


Job name/Part name 


Q'ty 


Remarks 


© 
© 
© 
© 
© 


3rd/4th pinion gear 

Circlip 

Washer 

5th 

Main axle 




For assembly, reverse the disassembly 
procedure. 



4-71 









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11650702 











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- 






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116507 


















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01 



TRANSMISSION 




EB413422 

CHECKING THE TRANSMISSION 

1. Measure: 
• main axle runout 
(with a centering device and dial gauge 

©) 

Out of specification -► Replace the main 
axle. 




Main axle runout limit 
0.02 mm 



2. Measure: 
• drive axle runout 
(with a centering device and dial gauge 

©) 

Out of specification -► Replace the drive 
axle. 




Drive axle runout limit 
0.02 mm 




3. Check: 

• transmission gears 

Blue discoloration/pitting/wear -► Re- 
place the defective gear(-s). 

• transmission gear dogs 
Cracks/damage/rounded edges -► Re- 
place the defective gear(-s). 



4. Check: 

• transmission gear engagement 

(each pinion gear to its respective wheel 

gear) 

Incorrect — ► Reassemble the transmission 

axle assemblies. 

5. Check: 

• transmission gear movement 

Rough movement -► Replace the defec- 
tive part(-s). 



Transmission gear reassembling point: 

Press the 2nd pinion gear ® into the main 
axle (D, as shown in the illustration. 



4-72 







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TRANSMISSION 




EB413710 

INSTALLING THE TRANSMISSION 

1. Install: 

• oil baffle plate ® 

• crankcase breather hose @ 

NOTE: 



Insert the metal clamp (3) on the crankcase 
breather hose into the slots ® in the crank- 
case. 



2. Install: 

• main axle assembly ® 

• drive axle assembly (D 

• oil seals 

• circlips 

• lock washer 





NOTE: 

• Make sure that the drive axle bearing cir- 
clips ® are inserted into the grooves ® in 
the upper crankcase. 

• The main axle bearing pin (§) must face to- 
wards the front of the crankcase and the 
drive axle bearing pin (6) must face to- 
wards the rear of the crankcase. 



3. Check: 
• transmission 
Rough movement 

NOTE: 



Repair. 



Oil each gear, shaft, and bearing thoroughly. 



4-73 



SHIFT DRUM AND SHIFT FORKS 



SHIFT DRUM AND SHIFT FORKS 




^ 10Nm(1.0nvkg) 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the shift drum and 
shift forks 




Remove the parts in the order listed. 




Disassembly the crankcase 
Transmission 




Refer to "CRANKCASE" section. 
Refer to "TRANSMISSION" section. 


1 
2 


Shift fork guide bar retainer 
Shift drum retainer 






3 
4 


Shift fork guide bar 1 
Shift fork C 




Refer to "INSTALLING THE SHIFT 


5 
6 


Shift fork guide bar 2 
Shift fork L 




FORKS AND SHIFT DRUM" section. 


7 


Shift fork R 






8 


Shift drum 




For installation, reverse the removal 
procedure. 



4-74 



SHIFT DRUM AND SHIFT FORKS 






11520401 



EB413400 

CHECKING THE SHIFT FORKS 

The following procedure applies to all of the shift 
forks and related components. 
1. Check: 

• shift fork cam follower ® 

• shift fork pawl (§) 
Bends/damage/scoring/wear -► Replace 
the shift fork. 



2. Check: 
• shift fork guide bar 
Roll the shift fork guide bar on a flat sur- 
face. 
Bend -► Replace. 



A WARNING 



Do not attempt to straighten a bent shift 
fork guide bar. 




3. Check: 
• shift fork movement 
(on the shift fork guide bar) 
Rough movement — ► Replace the shift 
forks and shift fork guide bar as a set. 




CHECKING THE SHIFT DRUM ASSEMBLY 

1. Check: 

• shift drum grooves 
Damage/scratches/wear -► Replace the 
shift drum. 

• shift drum segment ® 
Damage/wear -+ Replace. 

• shift drum bearing @ 
Damage/pitting -► Replace. 




INSTALLING THE SHIFT FORKS AND SHIFT 
DRUM ASSEMBLY 

1. Install: 
• shift drum assembly ® 



4-75 



SHIFT DRUM AND SHIFT FORKS 



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2. Install: 

• shift fork guide bars ® 

• shift fork "L" (2) 

• shift fork "C" ® 

• shift fork "R" ® 

NOTE: 



• The embossed marks on the shift forks 
should face towards the left side of the en- 
gine and be in the following sequence: "L", 
"C", "R". 

• The grooved side of the shift fork guide bar 
should face towards the right side of the 
engine. 



3. Install: 
• shift drum retainer ® 



10Nm(1.0m«kg) 



LOCKTITE 



shift fork guide bar retainer < 



"^ 10Nm(1.0m*kg)r 



4-76 



COOL 


X 



CHAPTER 5 
COOLING SYSTEM 



RADIATOR 5-1 

CHECKING THE RADIATOR 5-2 

INSTALLING THE RADIATOR 5-3 

THERMOSTAT 5-4 

CHECKING THE THERMOSTAT 5-6 

ASSEMBLING THE THERMOSTAT 5-7 

INSTALLING THE THERMOSTAT 5-7 

WATER PUMP 5-8 

REMOVING THE WATER PUMP 5-9 

CHECKING THE WATER PUMP 5-9 

INSTALLING THE WATER PUMP 5-9 



RADIATOR 



RADIATOR 



COOLING SYSTEM 



COOL 


X 




Order 


Job name/Part name 


Q'ty 


Remarks 


1 
2 
3 
4 
5 


Removing the radiator 

Seat 
Fuel tank 

Drain the coolant 

Fan motor leads 
Radiator outlet hose 
Radiator inlet hose 
Radiator 
Fan 




Remove the parts in the order listed. 

Refer to "FRONT COWLING/SEAT/SIDE 

COVER/FUEL TANK" section in chapter 

3. 

Refer to "CHANGING THE COOLANT" 

section in chapter 3. 

NOTE: 

Disconnect the coupler. 


For installation, reverse the removal 
procedure. 



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RADIATOR 



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EB500010 

CHECKING THE RADIATOR 

1. Check: 

• radiator fins 
Obstruction -► Clean. 

Apply compressed air to the rear of the ra- 
diator. 
Damage -► Repair or replace. 

NOTE: 

Straighten any flattened fins with a thin, flat- 
head screwdriver. 

2. Check: 

• radiator hoses 

• radiator pipes 
Cracks/damage -+ Replace. 

3. Measure: 

• radiator cap opening pressure 

Below the specified pressure -► Replace 
the radiator cap. 




Radiator cap opening pressure 
95 ~ 125 kPa 
(0.95 ~ 1.25 kg/cm 2 ) 



a. Install the radiator cap tester ® and 
adapter (2) to the radiator cap (3). 




Radiator cap tester 

90890-01325 
Adapter 

90890-01352 



b. Apply the specified pressure for ten se- 
conds and make sure that there is no drop 
in pressure. 

4. Check: 
• radiator fan 
Damage -► Replace. 
Malfunction — ► Check and repair. 
Refer to "COOLING SYSTEM" in chapter 
8. 



5-2 



RADIATOR 



COOL 


X 




EB500020 

INSTALLING THE RADIATOR 

1 . Fill: 

• cooling system 

(with the specified amount of the recom- 
mended coolant) 

Refer to "CHANGING THE COOLANT" in 
chapter 3. 

2. Check: 

• cooling system 

Leaks -+ Repair or replace any faulty part. 

a. Attach the radiator cap tester ® to the 
radiator. 




Radiator cap tester: 
90890-01325 



b. Apply 100 kPa (1.0 kg/cm 2 ) of pressure. 

c. Measure the indicated pressure with the 
gauge. 



5-3 



THERMOSTAT 



cool y^ 



THERMOSTAT 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the thermostat 




Remove the parts in the order listed. 




Seat 




i Refer to "FRONT COWLING/SEAT/ 
J SIDE COVER/FUEL TANK" section in 




Fuel tank 










chapter 3. 




Drain the coolant 




Refer to "CHANGING THE COOLANT" 
section in chapter 3. 


1 


Thermo switch lead 


1 


NOTE: 


2 


(engine temperature) 

Thermo switch lead (fan motor) 




Disconnect the lead. 


NOTE: 


3 
4 


Reservoir tank hose 
Carburetor inlet hose 




Disconnect the coupler. 




5 


Engine outlet hose 






6 


Engine outlet hose 






7 


Radiator inlet hose 






8 


Thermostat housing 






9 


Ground read 




For installation, reverse the removal 
procedure. 



5-4 



THERMOSTAT 



COOL 


X 



"^ 23 Nm (2.3 nvkg) 




8 Nm (0.8 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the thermostat 




Disassembly the parts in the order listed. 


® 


Thermo switch (fan motor) 






@ 


Thermo switch (engine temperature) 






(3) 


Thermostat housing cover 




Refer to "ASSEMBLING THE 


(3) 


O-ring 




THERMOSTAT" section. 


® 


Thermostat 






® 


Thermostat housing 




For assembly, reverse the disassembly 
procedure. 



5-5 



THERMOSTAT 




cool y^ 



[Rl 






i 


[Dj 




/ 






/ 


f 




8 mm 


rrr^^^^M 


/ 




i 


f 


[A^™^ - 








80.5°^ 


-83.5° 


95°C 


14250101 



EB502021 

CHECKING THE THERMOSTAT 

1. Check: 
• thermostat ® 
Does not open at 80.5 ~ 83.5°C -+ 
Replace. 

a. Suspend the thermostat in a container 
filled with water. 

b. Slowly heat the water. 

c. Place a thermometer in the water. 

d. While stirring the water, observe the ther- 
mometer's indicated temperature. 

© Thermometer 

(2) Water 

(3) Thermostat 
@ Container 
[A] Closes 

\E\ Opens 

NOTE: 

If the accuracy of the thermostat is in doubt, 
replace it. A faulty thermostat could cause 
serious overheating or overcooling. 




2. Check: 

• thermostat housing cover® 

• thermostat housing © 
Cracks/damage -► Replace. 

3. Measure: 

• radiator cap opening pressure 

Below the specified pressure -► Replace 

the radiator cap. 

Refer to "CHECKING THE RADIATOR". 

4. Check: 

• thermostat housing cover O-ring 

• thermostat inlet pipe O-ring 

• thermostat inlet pipe 

• water pump outlet pipe 
Damage -► Replace. 



5-6 



THERMOSTAT 




COOL 


X 



EB502030 

ASSEMBLING THE THERMOSTAT 

1. Install: 

• thermostat housing ® 

• thermostat @ 

• O-ring (New) ® 

• thermostat housing cover® 

NOTE: 



Install the thermostat with its breather hole 
® facing up. 



2. Install: 
• thermo switch (fan motor) ® 



23 Nm (2.3 m-kg) 



thermo switch (engine temperature) (2) 



8 Nm (0.8 rrvkg) 



CAUTION: 

Use extreme care when handling the 
thermo switch and temperature sender. 
Replace any part that was dropped or 
subjected to a strong impact. 



EB502040 

INSTALLING THE THERMOSTAT 

1 . Fill: 

• cooling system 

(with the specified amount of the recom- 
mended coolant) 

Refer to "CHANGING THE COOLANT" in 
chapter 3. 

2. Check: 

• cooling system 

Leaks -► Repair or replace any faulty part. 

3. Measure: 

• radiator cap opening pressure 

Below the specified pressure -► Replace 

the radiator cap. 

Refer to "CHECKING THE RADIATOR". 



5-7 



WATER PUMP 



WATER PUMP 



cool y^ 




10Nm(1.0irvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the water pump 

Drain the coolant 




Remove the parts in the order listed. 
Refer to "CHANGING THE 




Shift arm, drive chain cover 




COOLANT" section in chapter 3. 
Refer to "REMOVING THE ENGINE" 


1 


Radiator outlet hose 




section in chapter 4. 


2 
3 
4 
5 
6 
7 


Water pump outlet hose 

Water pump outlet pipe 

Water pump housing cover 

O-ring 

Water pump assembly 

O-ring 




i Refer to "REMOVING/INSTALLING THE 
J WATER PUMP" section. 

For installation, reverse the removal 

procedure. 



5-8 



WATER PUMP 




COOL 


X 



EB503020 

REMOVING THE WATER PUMP 

1. Remove: 
• water pump housing ® 

NOTE: 



Tap out the water pump seal from the inside 
of the water pump housing. 




EB503032 

CHECKING THE WATER PUMP 

1. Check: 

• water pump housing cover 

• water pump housing ® 

• impeller® 




2. Check: 

• water pump seal ® 

• oil seal (2) 
Cracks/damage/wear 



Replace. 




3. Check: 

• bearing ® 
Roughness -► Replace. 

4. Check: 

• water pump inlet pipe 

• radiator outlet hose 
Cracks/damage/wear - 



Replace. 




EB503052 

INSTALLING THE WATER PUMP 

1. Install: 
• water pump housing 



A WARNING 



Always use a new O-ring 



5-9 



WATER PUMP 




COOL J£ 



NOTE: 

• Align the slot @ on the impeller shaft with 
the projection ® on the oil pump shaft. 

• Before installing the water pump housing, 
apply a thin coat of lithium soap base 
grease onto the O-ring. 



2. Install: 

• water pump housing cover ® 

• water pump outlet pipe @ 



A WARNING 



Always use a new gasket and O-rings. 

NOTE: 

Before installing the water pump outlet pipe, 
apply a thin coat of lithium soap base grease 
onto the O-rings. 



x 



Water pump housing cover bolt 
10Nm(1.0iTTkg) * 



3. Install: 

• gasket 

• dowel pins 

• drive chain sprocke t cover ® 

"^ 10Nm(1.0nvkg) 



4. Install: 
• shift arm ® \\ 



10Nm(1.0nvkg) 



NOTE: 

Align the slot ® on the shift arm ® with the 
punch mark © on the shift shaft ©. 

5. Fill: 

• cooling system 

(with the specified amount of the recom- 
mended coolant) 

Refer to "CHANGING THE COOLANT" in 
chapter 3. 

6. Check: 

• cooling system 

Leaks -► Repair or replace any faulty part. 

7. Measure: 

• radiator cap opening pressure 

Below the specified pressure -► Replace 

the radiator cap. 

Refer to "CHECKING THE RADIATOR". 



5-10 



CHAPTER 6 
CARBURETORS 

CARBURETORS 6-1 

AIR FILTER CASE 6-1 

CARBURETORS 6-2 

CHECKING THE CARBURETORS 6-5 

ASSEMBLING THE CARBURETORS 6-7 

INSTALLING THE CARBURETORS 6-8 

MEASURING AND ADJUSTING THE FUEL LEVEL 6-9 

CHECKING AND ADJUSTING THE THROTTLE POSITION 

SENSOR 6-10 



CARB 


7 



CARBURETORS 

AIR FILTER CASE 



CARBURETORS 



CARBURETORS 



CARB 


7 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the air filter case 




Remove the parts in the order listed. 




Seat, fueltank and sidecovers 




Refer to "FRONT COWLING/SEAT/ 
SIDE COVER/FUEL TANK" section in 
chapter 3. 




Drain the coolant 




Refer to "CHANGING THE COOLANT" 
section. 


1 


Air filter case (left/right) 


1/1 




2 


Battery negative lead 


1 




3 


Battery positive lead 


1 




4 


Battery 


1 




5 


Stay 


1 


For installation, reverse the removal 
procedure. 



6-1 



CARBURETORS 



CARB 


9 



CARBURETORS 




Order 


Job name/Part name 


Q'ty 


Remarks 


1 
2 
3 


Removing the carburetors 

Throttle position sensor lead 
Air filter joint screw 
Carburetors joint screw 
Carburetor inlet/outlet hose 


4 

4 

1/1 


Remove the parts in the order listed. 

NOTE: 

Disconnect the coupler. 




4 
5 


Carburetors assembly 
Starter cable 


1 
1 




6 


Throttle cable 


2 


For installation, reverse the removal 
procedure. 



6-2 



CARBURETORS 



CARB 


7 




Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the carburetors 




Disassembly the parts in the order listed. 


© 


Starter plunger link 


1 




(D 


Carburetors assembly 


4 


#1 , #2, #3, #4 


(D 


Vacuum chamber cover 
Piston valve spring 
Piston valve 




" Refer to "ASSEMBLING THE 
CARBURETERS" section. 


© 


Needle kit 






® 


Float chamber 






® 


Float chamber gasket 






@ 


Float pin 






© 


Float 






© 


Needle valve assembly 






© 


Main jet 







6-3 



CARBURETORS 



CARB 


9 




Order 


Job name/Part name 


Q'ty 


Remarks 


© 
© 
© 
© 


Main jet holder 
Needle jet 
Pilot jet 
Pilot screw set 


1 
1 
1 
1 


Refer to "ASSEMBLING THE 
CARBURETORS" section. 


© 


Starter plunger kit 


1 


For assembly, reverse the disassembly 
procedure. 



6-4 



CARBURETORS 



CARB 


7 



EB600031 

CHECKING THE CARBURETORS 

The following procedure applies to all of the car- 
buretors. 

1. Check: 

• carburetor body 

• float chamber 

• main jet holder 
Cracks/damage -► Replace. 

2. Check: 

• fuel passages 
Obstruction -► Clean. 

a. Wash the carburetor in a petroleumbased 
solvent. Do not use any caustic-carbure- 
tor-cleaning solution. 

b. Blow out all of the passages and jets with 
compressed air. 




3. Check: 

• float chamber body ® 
Dirt -+ Clean. 

4. Check: 

• float chamber rubber gasket © 
Cracks/damage/wear -► Replace. 



5. Check: 
• float ® 
Damage 



Replace. 



6. Check: 

• needle valve ® 

• needle valve seat (2) 
Damage/obstruction/wear -► Replace the 
needle valve, needle valve seat and O-ring 
as a set. 

7. Check: 

• O-ring ® 

Damage/wear -► Replace the needle 
valve, needle valve seat and O-ring as a 
set. 



6-5 



CARBURETORS 




CARB 


9 



8. Check: 

• piston valve ® 
Damage/scratches/wear 

• rubber diaphragm ® 
Cracks/tears -► Replace. 



Replace. 



9. Check: 

• vacuum chamber cover ® 

• piston valve spring ® 

• jet needle holder® 
Cracks/damage -► Replace. 



10. Check: 

• jet needle kit ® 

• needle jet© 

• main jet® 

• pilot jet® 

• pilot screw ® 

• starter plunger® 
Bends/damage/wear -► Replace. 
Obstruction -► Clean. 

Blow out the jets with compressed air. 



11. Check: 

• piston valve movement 

Insert the piston valve into the carburetor 
body and move it up and down. 
Tightness -► Replace the piston valve. 

12. Check: 

• fuel feed pipes 

• hose joint 
Cracks/damage -+ Replace. 
Obstruction -► Clean. 

Blow out the pipes with compressed air. 

13. Check: 

• fuel hoses 
Cracks/damage/wear -► Replace. 
Obstruction -► Clean. 

Blow out the hoses with compressed air. 



6-6 



CARBURETORS 



CARB 


7 



ASSEMBLING THE CARBURETORS 

The following procedure applies to all of the car- 
buretors. 




CAUTION: 

• Before assembling the carburetors, 
wash all of the parts in a petroleum- 
based solvent. 

• Always use a new gasket. 

Install: 

• O-ring (New) 

• washer 

• pilot screw spring 

• pilot screw CD 




Pilot screw 
2 turns out 



2. Install: 

• jet needle ® 

• washer® (0.5 mm) 

• ring ® 

• clip® 

• washer® (0.5 mm) 




Standard clip position: 
No. 3 Groove 



3. Install: 

• piston valve 

• jet needle kit ® 

• jet needle holder® 

• piston valve spring ® 

• vacuum chamber cover 

NOTE: 



• Insert the end of the piston valve spring 
onto the spring guide on the vacuum 
chamber cover. 

• Align the tab on the piston valve dia- 
phragm with the recess in the carburetor 
body. 



6-7 



CARBURETORS 




CARB 


9 



4. Install: 

• fuel feed joints ® 

• hose joints @ 

• spacer (§) 

• connecting bolt ® 

• starter plunger link® 

• throttle cable holder d 

• spacer (7) 

• connecting bolt ® 

NOTE: 



• Do not tighten the connecting bolts yet. 

• Install the throttle arm (D onto carburetors 
#1 , #2, and #4 between the spring © and 
synchronizing screw ©. 

• Install the starter plunger link onto each 
starter plunger. 

• Place the carburetor assembly on a sur- 
face plate with the intake manifold side 
down. Then, tighten the connecting bolts 
while pushing down the carburetor assem- 
bly with an even force. 

• After tightening the connecting bolts, 
check that the throttle cable lever and 
starter plunger link operate smoothly. 



EB600051 

INSTALLING THE CARBURETORS 

1 . Adjust: 

• carburetor synchronization 

Refer to "SYNCHRONIZING THE CAR- 
BURETORS" in chapter 3. 

2. Adjust: 

• engine idling speed 



€\ 



Engine idling speed 
1,150 ~ 1,250 r/min 



Refer to "ADJUSTING THE ENGINE ID- 
LING SPEED" in chapter 3. 

3. Adjust: 
• throttle cable free play 




Throttle cable free play (at the 
flange of the throttle grip) 
3 — 5 mm 



Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY" in chapter 3. 



6-8 





CARBURETORS 



CARB 


7 



EB600062 

MEASURING AND ADJUSTING THE FUEL 
LEVEL 

1. Measure: 
• fuel level ® 
Out of specification -+ Adjust 




Fuel level (above the float 
chamber mating surface) 
4.5 mm 



a. Stand the motorcycle on a level surface. 

b. Place the motorcycle on a suitable stand 
to ensure that the motorcycle is standing 
straight up. 

c. Install the fuel level gauge ® to the fuel 
drain pipe®. 




Fuel level gauge 
90890-01312 



d. Loosen the fuel drain screw ® . 

e. Hold the fuel level gauge vertically next to 
the float chamber. 

f. Measure the fuel level (§). 

NOTE: 

Fuel level readings should be equal on both 
sides of the carburetor assembly. 



2. Adjust: 
• fuel level 




a. Remove the carburetor assembly. 

b. Check the needle valve seat and needle 
valve. 

c. If either is worn, replace them as a set. 

d. If both are fine, adjust the float level by 
slightly bending the float tang ®. 

e. Install the carburetor assembly. 

f. Measure the fuel level again. 

g. Repeat steps (a) to (f) until the fuel level is 
within specification. 



6-9 



CARBURETORS 



CARB 


9 



B/L 


Y 


L 



3_C 



B/L Y L 



-L- 
Y- 

B/L- 



EB600070 

CHECKING AND ADJUSTING THE 
THROTTLE POSITION SENSOR 

NOTE: 



Before adjusting the throttle position sen- 
sor, the engine idling speed should be 
properly adjusted. 

When installing the throttle position sen- 
sor, adjust its angle according to the RPM 
which is displayed on the tachometer. 
Refer to the adjustment procedure below. 



1. Check: 
• throttle position sensor 



a. Disconnect the throttle position sensor 
coupler. 

b. Connect the pocket tester (£2 x 1k) to the 
throttle position sensor. 



Tester positive lead - 
Tester negative lead 



BLUE® 
BLACK/BLUE 

® 



c. Check the throttle position sensor maxi- 
mum resistance. 

Out of specification -► Replace the 
throttle position sensor. 




Throttle position sensor 
maximum resistance 
3.5 ~ 6.5 W£l at 20°C 
(BLUE — BLACK/BLUE) 



d. Install the throttle position sensor onto the 
carburetor. 

e. Connect the pocket tester (£2 x 1k) to the 
throttle position sensor. 



Tester positive lead - 
Tester negative lead 



YELLOW® 
BLACK/BLUE 



f. While slowly opening the throttle, check 
that the throttle position sensor resis- 
tance is within the specified range. 
Out of specification -► Replace the 
throttle position sensor. 




Throttle position sensor 

resistance 
~ 5±1.5kftat20°C 
(YELLOW — BLACK/BLUE) 



2. Adjust: 
• throttle position sensor angle 

a. Turn the main switch to "ON". 



6-10 



CARBURETORS 



CARB 


7 




b. Disconnect the throttle position sensor 
coupler. 

c. Reconnect the throttle position sensor 
coupler. 

NOTE: 

After reconnecting the throttle position sen- 
sor coupler, the tachometer switches to the 
throttle position sensor adjustment mode. 

d. Loosen the throttle position sensor 
screws®. 

e. Adjust the throttle position sensor angle 
according to the following table: 

NOTE: 

The angle of the throttle position sensor is in- 
dicated by the RPM which is displayed on 
the tachometer. 



Tachometer 
Reading 


Throttle 

position 

sensor angle 


Adjust- 
ment 
direction 


5000 rpm ® 


Correct 




Orpm (§) 


Incorrect 


® 


10000 rpm (3) 


Incorrect 


© 



f . After adjusting the throttle position sensor 
angle, tighten the throttle position sensor 
screws. 

NOTE: 

To exit the throttle position sensor adjust- 
ment mode, start the engine or turn the main 
switch to "OFF". 



6-11 




CHAPTER 7 
CHASSIS 



FRONT WHEEL AND BRAKE DISCS 7-1 

FRONT WHEEL 7-2 

REMOVING THE FRONT WHEEL 7-3 

CHECKING THE FRONT WHEEL 7-3 

CHECKING THE BRAKE DISCS 7-5 

INSTALLING THE FRONT WHEEL 7-6 

ADJUSTING THE FRONT WHEEL STATIC BALANCE 7-7 

REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET 7-8 

REAR WHEEL 7-8 

BRAKE DISC AND REAR WHEEL SPROCKET 7-9 

DISASSEMBLY THE REAR WHEEL 7-10 

REMOVING THE REAR WHEEL 7-11 

CHECKING THE REAR WHEEL 7-11 

CHECKING AND REPLACING THE REAR WHEEL SPROCKET 7-12 

INSTALLING THE REAR WHEEL 7-12 

ADJUSTING THE REAR WHEEL STATIC BALANCE 7-13 

FRONT AND REAR BRAKES 7-14 

FRONT BRAKE PADS 7-14 

REAR BRAKE PADS 7-15 

REPLACING THE FRONT BRAKE PADS 7-16 

REPLACING THE REAR BRAKE PADS 7-18 

FRONT BRAKE MASTER CYLINDER 7-20 

REAR BRAKE MASTER CYLINDER 7-22 

REMOVING THE FRONT BRAKE MASTER CYLINDER 7-24 

REMOVING THE REAR BREAKE MASTER CYLINDER 7-24 

CHECKING THE FRONT AND REAR BRAKE MASTER 

CYLINDERS 7-25 

ASSEMBLING AND INSTALLING THE FRONT BRAKE 

MASTER CYLINDER 7-26 

ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER . . 7-27 

FRONT BRAKE CALIPERS 7-29 

REAR BRAKE CALIPER 7-31 

DISASSEMBLING THE FRONT BRAKE CALIPER 7-33 

DISASSEMBLING THE REAR BRAKE CALIPER 7-34 

CHECKING THE FRONT AND REAR BRAKE CALIPERS 7-34 

ASSEMBLING AND INSTALLING THE FRONT BRAKE 

CALIPERS 7-35 

ASSEMBLING AND INSTALLING THE REAR BRAKE 

CALIPER 7-37 

FRONT FORK 7-40 

REMOVING THE FRONT FORK LEGS 7-43 

DISASSEMBLING THE FRONT FORK LEGS 7-43 

CHECKING THE FRONT FORK LEGS 7-44 

ASSEMBLING THE FRONT FORK LEGS 7-45 

INSTALLING THE FRONT FORK LEGS 7-47 

HANDLEBAR 7-48 

REMOVING THE HANDLEBAR 7-50 

CHECKING THE HANDLEBAR 7-50 

INSTALLING THE HANDLEBAR 7-51 




STEERING HEAD 7-53 

LOWER BRACKET 7-53 

REMOVING THE LOWER BRACKET 7-55 

CHECKING THE STEERING HEAD 7-55 

INSTALLING THE STEERING HEAD 7-56 

REAR SHOCK ABSORBER AND RELAY ARM 7-57 

HANDLING THE REAR SHOCK ABSORBER 7-59 

DISPOSING OF A REAR SHOCK ABSORBER 7-59 

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 7-60 

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 7-61 

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 7-61 

SWINGARM AND DRIVE CHAIN 7-62 

REMOVING THE SWINGARM 7-64 

CHECKING THE SWINGARM 7-65 

CHECKING THE DRIVE CHAIN 7-66 

INSTALLING THE SWINGARM 7-67 

INSTALLING THE DRIVE CHAIN 7-68 



FRONT WHEEL AND BRAKE DISC 



CHASSIS 
FRONT WHEEL AND BRAKE DISC 




40 Nm(4.0 rrrkg) 




23 Nm(2.3 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the flont wheel and brake 
discs 




Remove the parts in the order listed. 


1 

2 
3 

4 


Wheel axle pinch bolt 

Brake hose horder (left/right) 
Brake caliper (left/right) 
Wheel axle 


1 

1/1 
1/1" 
1 


NOTE: 

Loosen 


Refer to "REMOVING/INSTALLING THE 


5 
6 

7 


Front wheel assembly 
Speed sensor unit 
Collar 


1 

1 - 
1 


FRONT WHEEL" section. 


8 


Brake disc (left/right) 


1/1 


For installation, reverse the removal 
procedure. 



7-1 



FRONT WHEEL AND BRAKE DISC 



FRONT WHEEL 





Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the front wheel 




Disassembly the parts in the order listed. 


® 


Oil seal 


1 




(2) 


Bearing 


1 




® 


Spacer 


1 




<D 


Bearing 


1 


For assembly, reverse the disassembly 
prodedure. 



7-2 



FRONT WHEEL AND BRAKE DISC 





EB700102 

REMOVING THE FRONT WHEEL 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

NOTE: 

Place the motorcycle on a suitable stand so 
that the front wheel is elevated. 

2. Remove: 

• wheel axle pinch bolt 

• brake hose holder (left/right) 

3. Remove: 

• left brake caliper 

• right brake caliper 

NOTE: 

Do not squeeze the brake lever when re- 
moving the brake calipers. 

4. Remove: 

• Wheel axle 

• Speed sensor unit ® 

CAUTION: 



Push the front wheel rearward and 
remove the speed sensor unit (D from the 
front wheel. 

5. Elevate: 
• front wheel 

NOTE: 

Place the motorcycle on a suitable stand so 
that the front wheel is elevated. 




EB700400 

CHECKING THE FRONT WHEEL 

1. Measure: 
• wheel axle runout 




Wheel axle runout 
<Limit> 0.25 mm 



A WARNING 



Do not attempt to straighten a bent wheel 
axle. 

2. Check: 

• tire 

• front wheel 
Damage/wear -► Replace. 

Refer to "CHECKING THE TIRES" and 
"ICHECKING THE WHEELS" in chapter 3. 



7-3 



FRONT WHEEL AND BRAKE DISC 





Z- 


® f> 








3. Measure: 

• front wheel radial runout ® 

• front wheel lateral runout ® 

Over the specified limits -► Replace. 




Front wheel radial runout limit 

1.0 mm 
Front wheel lateral runout limit 

0.5 mm 



4. Check: 

• wheel bearings 

Front wheel turns roughly or is loose 
Replace the wheel bearings. 

• oil seals 
Damage/wear -► Replace. 



5. Replace: 

• wheel bearings (New) 

• oil seals (New) 



a. Clean the outside of the front wheel hub. 

b. Remove the oil seals ® with a flat-head 
screwdriver. 

NOTE: 

To prevent damaging the wheel, place a rag 
(D between the screwdriver and the wheel 
surface. 

c. Remove the wheel bearings ® with a 
general bearing puller®. 

d. install the new wheel bearings and oil 
seals in the reverse order of disassembly. 

CAUTION: 



Do not contact the wheel bearing center 
race ® or balls ®. Contact should be 
made only with the outer race (7). 

NOTE: 

Use a socket ® that matches the diameter 
of the wheel bearing outer race and oil seal. 



7-4 



FRONT WHEEL AND BRAKE DISC 





EB700414 

CHECKING THE BRAKE DISCS 

The following procedure applies to all of the 
brake discs. 

1. Check: 

• brake disc 
Damage/galling -► Replace. 

2. Measure: 

• brake disc deflection (§) 

Out of specification -► Correct the brake 
disc deflection or replace the brake disc. 




Brake disc deflection limit 
(maximum) 

Front: 0,2 mm 

Rear: 0.15 mm 



a. Place the motorcycle on a suitable stand 
so that the wheel is elevated. 

b. Before measuring the front brake disc 
deflection, turn the handlebar to the left or 
right to ensure that the front wheel is sta- 
tionary. 

c. Remove the brake caliper. 

d. Hold the dial gauge at a right angle 
against the brake disc surface. 

e. Measure the deflection 2 — 3 mm below 
the edge of the brake disc. 



3. Measure: 
• brake disc thickness © 
Measure the brake disc thickness at a few 
different locations. 
Out of specification -► Replace. 





Brake disc thickness limit 
(minimum) 

Front: 3,5 mm 

Rear: 4.5 mm 



, Adjust: 
• brake disc deflection 



a. Remove the brake disc. 

b. Rotate the brake disc by one bolt hole. 

c. Install the brake disc. 

NOTE: 

Tighten the brake disc bolts ® in stages and 
in a crisscross pattern. 



V 



Brake disc bolt LOCKTITE^ 
23 Nm (2.3 irrkg) 



d. Measure the brake disc deflection. 

e. If out of specification, repeat the adjust- 
ment steps until the brake disc deflection 
is within specification. 

f. If the brake disc deflection cannot be 
brought within specification, replace the 
brake disc. 



7-5 



FRONT WHEEL AND BRAKE DISC 




EB700722 

INSTALLING THE FRONT WHEEL 



1 . Lubricate: 

• wheel axle 

• wheel bearings 

• oil seal lips 



Recommended lubricant 
Lithium soap base grease 




2. Install: 
• Speed sensor unit 

NOTE: 



Make sure that the speed sensor unit and 
the wheel hud are installed with the two pro- 
jections @ meshed into the two slots ® re- 
spectively. 



3. Install: 
• front wheel 

NOTE: 



Make sure that the slot (§) in the speed sen- 
sor unit fits over the stopper on the outer 
tube®. 

4. Tighten: 

• wheel axle 

• wheel axle pinch bolt 

• brake caliper bolts 



Wheel axle 

67 Nm (6.7 irrkg) 
Wheel axle pinch bolt 

20 Nm (2.0 irrkg) 
Brake caliper bolt 

40 Nm (4.0 nvkg) 



A WARNING 



Make sure that the brake cable is routed 
properly. 

CAUTION: 

Before tightening the wheel axle nut, 
push down hard on the handlebar sever- 
al times and check if the front fork re- 
bounds smoothly. 



7-6 



FRONT WHEEL AND BRAKE DISC 





BT 




1ST 





ADJUSTING THE FRONT WHEEL STATIC 
BALANCE 

NOTE: 

• After replacing the tire, wheel or both, the 
front wheel static balance should be ad- 
justed. 

• Adjust the front wheel static balance with 
the brake discs installed. 

1. Remove: 

• balancing weight(-s) 

NOTE: 

Place the front wheel on a suitable balancing 
stand. 



2. Find: 
• front wheel's heavy spot 



a. Spin the front wheel 

b. When the front wheel stops, put an "X-|" 
mark at the bottom of the wheel. 

c. Turn the front wheel 90° so that the "X-|" 
mark is positioned as shown [A]. 

d. Release the front wheel. 

e. When the wheel stops, put an "X 2 " mark 
at the bottom of the wheel \M . 

f. Repeat steps (b) through (d) several 
times until all the marks come to rest at 
the same spot. 

g. The spot where all the marks come to rest 
is the front wheel's heavy spot "X". 

3. Adjust: 
• front wheel static balance 

a. Install a balancing weight ® onto the rim 
exactly opposite the heavy spot "X" [C] . 

NOTE: 

Start with the lightest weight. 

b. Turn the front wheel 90 ° so that the heavy 
spot is positioned as shown \D\ . 

c. If the heavy spot does not stay in that 
position, install a heavier weight. 

d. Repeat steps (b) and (c) until the front 
wheel is balanced. 



4. Check: 
• front wheel static balance 



a. Turn the front wheel and make sure that it 
stays at each position shown. 

b. If the front wheel does not remain station- 
ary at all of the positions, rebalance it. 



7-7 



REAR WHEEL, BRAKE DISC 
AND REAR WHEEL SPROCKET 



REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET 

REAR WHEEL 





40 Nm (4.0 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


1 
2 


Removing the rear wheel 

Brake caliper 
Nut 




Remove the parts in the order listed. 


3 


Washer 






4 


Wheel axle 




Refer to "REMOVING/INSTALLING THE 


5 


Washer 




REAR WHEEL" section. 


6 

7 
8 


Drive chain puller (left) 
Drive chain puller (right) 
Rear wheel assembly 




For installation, reverse the removal 
procedure. 



7-8 



REAR WHEEL, BRAKE DISC 
AND REAR WHEEL SPROCKET 



BRAKE DISC AND REAR WHEEL SPROCKET 




^ 60 Nm (6.0 nvkg) 




Order 


Job name/Part name 


Q'ty 


Remarks 


1 
2 


Removing the brake disk and rear 
wheel sprocket 

Collar (left/right) 
Brake disc 


1/1 
1 


Remove the parts in the order listed. 


3 

4 


Rear wheel sprocket 
Collar 


1 
1 




5 
6 


Drive hub damper 
Rear wheel drive hub 


6 
1 




7 


Oil seal 


1 




8 


Bearing 


1 


For instalation, reverse the removal 
procedure. 



7-9 



REAR WHEEL, BRAKE DISC 
AND REAR WHEEL SPROCKET 




DIASSEMBLY THE REAR WHEEL 




Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the rear wheel 




Disassembly the parts in the order listed. 


© 


Oil seal 


1 




© 


Bearing 


1 




® 


Collar 


1 




© 


Bearing 


1 


For assembly, reverse the disassembly 
procedure. 



7-10 



REAR WHEEL, BRAKE DISC 
AND REAR WHEEL SPROCKET 




EB701100 

REMOVING THE REAR WHEEL 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so. that 
there is no danger of it falling over. 

NOTE: 

Place the motorcycle on a suitable stand so 
that the rear wheel is elevated. 



/ / 

/( 








^^oi 











2. Remove: 
• brake caliper® 

NOTE: 



Do not depress the brake pedal when re- 
moving the brake caliper. 




3. Loosen: 

• locknut ® 

• adjusting nut @ 

4. Remove: 

• wheel axle nut (£ 

• wheel axle (3) 

• rear wheel 

NOTE: 



Push the rear wheel forward and remove the 
drive chain from the rear wheel sprocket. 

5. Remove: 

• left collar® 

• rear wheel drive hub (D 

• rear wheel drive hub damper ® 

• right collar 

EB701400 

CHECKING THE REAR WHEEL 

1. Check: 

• wheel axle 

• rear wheel 

• wheel bearings 

• oil seals 

Refer to "FRONT WHEEL AND BRAKE 
DISC" 

2. Check: 

• tire 

• rear wheel 
Damage/wear -t- Replace. 

Refer to "CHECKING THE TIRES" and 
"CHECKING THE WHEELS" in chapter 3. 



7-11 



REAR WHEEL, BRAKE DISC 
AND REAR WHEEL SPROCKET 





3. Measure: 

• rear wheel radial runout 

• rear wheel lateral runout 

Refer to "FRONT WHEEL AND BRAKE 
DISC". 

EB701440 

CHECKING AND REPLACING THE REAR 
WHEEL SPROCKET 

1. Check: 

• rear wheel sprocket 

More than 1 /4 tooth (a) wear -► Replace 

the rear wheel sprocket. 

Bent teeth -► Replace the rear wheel 

sprocket. 

• correct © 

• drive chain roller® 

• rear wheel sprocket (D 



2. Replace: 
• rear wheel sprocket ® 



a. Remove the self-locking nuts and the rear 
wheel sprocket. 

b. Clean the rear wheel drive hub with a 
clean cloth, especially the surfaces that 
contact the sprocket. 

c. Install the new rear wheel sprocket. 



Rear wheel sprocket 
self-locking nut 
60 Nm (6.0 nvkg) 



NOTE: 

Tighten the self-locking nuts (2) in stages 
and in a crisscross pattern. 



EB701711 

INSTALLING THE REAR WHEEL 



1 . Lubricate: 

• wheel axle 

• wheel bearings 

• oil seal lips 



Recommended lubricant 
Lithium soap base grease 



2. Tighten: 

• wheel axle nut 

• brake caliper bolts 



V 



Wheel axle nut 

117 Nm (11.7 irrkg) 
Brake caliper bolt 

40 Nm (4.0 irrkg) 



7-12 



REAR WHEEL, BRAKE DISC 
AND REAR WHEEL SPROCKET 




EB701900 

ADJUSTING THE REAR WHEEL STATIC 
BALANCE 

NOTE: 

• After replacing the tire, wheel or both, the 
rear wheel static balance should be ad- 
justed. 

• Adjust the rear wheel static balance with 
the brake disc and rear wheel drive hub 
installed. 

1 . Adjust: 

• rear wheel static balance 

Refer to "FRONT WHEEL AND BRAKE 
DISC". 



7-13 



FRONT AND REAR BRAKES 




FRONT AND REAR BRAKES 

FRONT BRAKE PADS 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the front brake pads 




Remove the parts in the order listed. 


1 


Brake caliper 


1 




2 


Brake pads clip 


2 - 




3 


Brake pad pin 


1 


Refer to "REPLACING THE FRONT 


4 


Brake pad spring 


1 


BRAKE PADS" section. 


5 


Brake pad 


2 - 


For installation, reverse the removal 
procedure. 



7-14 



REAR BRAKE PADS 



FRONT AND REAR BRAKES 





"^ 40 Nm (4.0 nvkg) 



10Nm(1.0nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the rear brake pads 




Remove the parts in the order listed. 


1 


Caliper 


1 - 




2 


Brake pad pin 


2 


Refer to "REPLACING THE REAR 


3 


Brake pad/shim 


2/2 


BRAKE PADS" section. 


4 


Brake pad spring 


1 - 


For instalation, reverse the removal 
procedure. 



7-15 



FRONT AND REAR BRAKES 




CAUTION: 

Disc brake componets rarely require dis- 
assembly. 

Tehrefore, always follow these preven- 
tive measures: 

• Never disassemble brake components 
unless absolutely necessary. 

• If any connection on the hydraulic 
brake system is disconnected, the en- 
tire brake system must be disas- 
sembled, drained, cleaned, properly 
filled, and bled after reassembly. 

• Never use solvents on internal brake 
components. 

• Use only clean or new brake fluid for 
cleaning brake components. 

• Brake fluid may damage painted sur- 
faces and plastic parts. Therefore, al- 
ways clean up any spilt fluid immedi- 
ately. 

• Avoid brake fluid coming into contact 
with the eyes as it can cause serious in- 
jury. 

First aid for brake fluid entering the eyes: 

• Flush with water for 1 5 minutes and get 
immediate medical attention. 




REPLACING THE FRONT BRAKES PADS 

The following procedure applies to both brake 
calipers. 

NOTE: 

When replacing the brake pads, it is not nec- 
essary to disconnect the brake hose or dis- 
assemble the brake caliper. 

1. Remove: 

• brake hose holder ® 

• speedometer cable guide @ 

• brake caliper® 

2. Remove: 

• brake pad clips ® 

• brake pad pins (2) 

• brake pad spring ® 



7-16 



FRONT AND REAR BRAKES 





3. Remove: 

• brake pads ® 

(along with the brake pad shims) 

4. Measure: 

• brake pad wear limit ® 

Out of specification -► Replace the brake 
pads as a set. 




Brake pad wear limit 
0.5 mm 



5. Install: 

• brake pad shims 
(onto the brake pads) 

• brake pads 

• brake pad spring 

NOTE: 



Always install new brake pads, brake pad 
shims, and a brake pad spring as a set. 

a. Connect a clear plastic hose ® tightly to 
the bleed screw (2). Put the other end of 
the hose into an open container. 

b. Loosen the bleed screw and push the 
brake caliper pistons into the brake cali- 
per with your finger. 

c. Tighten the bleed screw. 



6 Nm (0.6 rrrkg) 



Install new brake pad shims onto the new 
brake pads. 

Install new brake pads and a new brake 
pad spring. 



6. Install: 

• brake pad spring 

• brake pad pins (T) 

• brake pad clipsjS) 

• brake caliper 



40 Nm (4.0 rrvkg) 



NOTE: 

The arrow (§) on the brake pad spring must 
point in the direction of disc rotation. 

7. Check: 

• brake fluid level 

Below the minimum level mark ® — ► Add 

the recommended brake fluid to the proper 

level. 

Refer to "CHECKING THE BRAKE FLUID 

LEVEL" in chapter 3. 

8. Check: 

• brake lever operation 

Soft or spongy feeling -► Bleed the brake 

system. 

Refer to "BLEEDING THE HYDRAULIC 

BRAKE SYSTEM" in chapter 3. 



7-17 



FRONT AND REAR BRAKES 




/ / 

/ ( 




VJ® ^^' 


M?J 




]^\^^^ 


Vr^fc 


^^t 















<3) 


m 




'jS$mp)A 




/JM 


WW 




/ ^&k 


( / 





s 



^v 



1 !L 



'■^2 



12220404 




^(^~X~^- 


fT\ 


lS 


($) 


l^^^=^=^^k^ 




12220502 



REPLACING THE REAR BRAKE PADS 
NOTE: 



When replacing the brake pads, it is not nec- 
essary to disconnect the brake hose or dis- 
assemble the brake caliper. 



1. Remove: 
• brake caliper® 



2. Remove: 

• brake pad pins ® 

3. Remove: 

• brake pads (2) 

(along with the brake pad shims) 

• brake pad spring 



4. Measure: 
• brake pad wear limit (§) 
Out of specification -► Replace the brake 
pads as a set. 




Brake pad wear limit 
0.5 mm 



5. Install 

• brake pad shims 
(onto the brake pads) 

• brake pads 

• brake pad spring 

NOTE: 



Always install new brake pads, brake pad 
shims, and a brake pad spring as a set. 

a. Connect a clear plastic hose ® tightly to 
the bleed screw (2). Put the other end of 
the hose into an open container. 

b. Loosen the bleed screw and push the 
brake caliper pistons into the brake cali- 
per with your finger. 
Tighten the bleed screw. 



c. 



6 Nm (6 nvkg) 



d. Install a new brake pad shim (3) onto each 
new brake pad (3). 

e. Install new brake pads and a new brake 
pad spring. 



7-18 



FRONT AND REAR BRAKES 





6. Install: 

• brake pad pins ® [\ 

• brake caliper 



10Nm(1.0nrkg) 



40 Nm (4.0 rrvkg) 



7. Check: 
• brake fluid level 
Below the minimum level mark (a) — ► Add 
the recommended brake fluid to the proper 
level. 

Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 



8. Check: 
• brake lever operation 
Soft or spongy feeling -► Bleed the brake 
system. 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 



7-19 



FRONT AND REAR BRAKES 



FRONT BRAKE MASTER CYLINDER 





10Nm(1.0nvkg) 



^ 30 Nm(3.0 nvkg) 4 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the front brake master 




Remove the parts in the order listed. 




cylinder 








Drain the brake fluid 






1 


Brake lever 


1 




2 


Brake switch lead 


2 




3 


Brake switch 


1 




4 
5 
6 

7 


Union bolt 

Copper washer/brake hose 
Master cylinder bracket 
Master cylinder 


1 - 
2/1 
1 
1 - 


" Refer to "REMOVING/ASSEMBLING 
AND INSTALLING THE FRONT BRAKE 
MASTER CYLINDER" section. 

For installation, reverse the removal 
procedure. 



7-20 



FRONT AND REAR BRAKES 





Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the front brake 




Disassembly the parts in the order listed. 




master cylinder 






® 


Master cylinder boot 


1 




@ 


Circlip 


1 




@ 


Master cylinder kit 


1 




(3) 


Spring 


1 


For assembly, reverse the disassembly 
procedure. 



7-21 



FRONT AND REAR BRAKES 



REAR BRAKE MASTER CYLINDER 




^ 4 Nm(0.4 m»kg) 




^ 23 Nm(2.3 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the rear brake master 




Remove the parts in the order listed. 




cylinder 








Side cover (right) 








Drain the brake fluid 






1 


Master cylinder bolt 


2 




2 


Union bolt 


1 - 


-, Refer to "REMOVING/ASSEMBLING 
J AND INSTALLING THE REAR BRAKE 


3 


Copper washer/brake hose 


2/1- 








MASTER CYLINDER" section. 


4 


Clip/hose 


2/1 




5 


Cotter pin 


1 




6 


Pin 


1 




7 


Washer 


1 




8 


Master cylinder 


1 


For installation, reverse the removal 
procedure. 



7-22 



FRONT AND REAR BRAKES 





Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the rear brake master 




Disassembly the parts in the order listed. 




cylinder 









Master cylinder boot 


1 




® 


Circlip 


1 




(3) 


Master cylinder kit 


1 




(3) 


Spring 


1 


For assembly, reverse the disassembly 
procedure. 



7-23 



FRONT AND REAR BRAKES 




EB702210 

REMOVING THE FRONT BRAKE MASTER 
CYLINDER 

NOTE: 

Befor disassembling the front brake master 
cylinder, drain the brake fluid from the entire 
brake system. 









^^O^N 






5^ 


-® \\ 


s^****Z. 






~~@ ,-. 




=3d^St 


«^rH \ 




c£^" 


§V7 


Y^k 





1. Disconnect: 

• brake switch coupler ® 
(from the brake switch) 

2. Remove: 

• union bolt© 

• copper washers ® 

• brake hoses ® 

NOTE: 



To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose. 




EB702220 

REMOVING THE REAR BRAKE MASTER 
CYLINDER 

1. Remove: 

• side cover right 

2. Remove: 

• union bolt® 

• copper washers ® 

• brake hose ® 

NOTE: 

To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose. 



7-24 



FRONT AND REAR BRAKES 




A| 




Bj 


1 

b^3 





w 



w 





EB702242 

CHECKING THE FRONT AND REAR BRAKE 
MASTER CYLINDERS 

The following procedure applies to the both of 
the brake master cylinders. 

1. Check: 

• brake master cylinder 
Damage/scratches/wea -► Replace. 

• brake fluid delivery passages 
(brake master cylinder body) 
Obstruction — ► Blow out with compressed 
air. 

El Front 
\E Rear 

2. Check: 

• brake master cylinder kit ® 
Damage/scratches/wear -► Replace. 

[C| Front 
\D\ Rear 





3. Check: 

• rear brake fluid reservoir ® 
Cracks/damage -► Replace. 

• rear brake fluid reservoir diaphragm 
Cracks/damage -► Replace. 





y® 


ff m " " /"*> 




^CZ 


( 1" 













4. Check 
• front brake master cylinder diaphragm ® 
Damage/wear -► Replace. 




5. Check: 
• brake hoses ® 
Cracks/damage/wear 



Replace. 



7-25 



FRONT AND REAR BRAKES 




EB702270 

ASSEMBLING AND INSTALLING THE 
FRONT BRAKE MASTER CYLINDER 




A WARNING 



Before installation, all internal brake 
components should be cleaned and lu- 
bricated with clean or new brake fluid. 
Never use solvents on internal brake 
components. 




1. Install: 

• copper washers (New) ® 

• brake hose (T 

• union bolt® 



30 Nm (3.0 irvkg) 



A WARNING 



Proper brake hose routing is essential to 
insure safe motorcycle operation. Refer 
to "CABLE ROUTING". 



CAUTION: "^^^^^^^^ 

When installing the brake hose onto the 
brake master cylinder, make sure that the 
brake pipe touches the projection (a) on 
the brake master cylinder. 

NOTE: 

• While holding the brake hose, tighten the 
union bolt as shown. 

• Turn the handlebar to the left and to the 
right to make sure that the brake hose 
does not touch other parts (e.g, wire har- 
ness, cables, leads). Correct if necessary. 



2. Fill: 



brake master cylinder reservoir 
(with the specified amount of the recom- 
mended brake fluid) 



*Q 



Recommended brake fluid 
DOT 4 



A WARNING 



• Use only the designated brake fluid. 
Other brake fluids may cause the 
rubber seals to deteriorate, causing 
leakage and poor brake performance. 

• Refill with the same type of brake fluid 
that is already in the system. Mixing 
brake fluids may result in a harmful 
chemical reaction, leading to poor 
brake performance. 

• When refilling, be careful that water 
does not enter the reservoir. Water will 
significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock. 



7-26 



FRONT AND REAR BRAKES 





CAUTION: 

Brake fluid may damage painted 
surfaces and plastic parts. Therefore, 
always clean up any spilt brake fluid 
immediately. 

3. Bleed: 

• brake system 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 

4. Check: 

• brake fluid level 

Below the minimum level mark (a) — ► Add 

the recommended brake fluid to the proper 

level. 

Refer to "CHECKING THE BRAKE FLUID 

LEVEL" in chapter 3. 

5. Check: 

• brake lever operation 

Soft or spongy feeling -► Bleed the brake 

system. 

Refer to "BLEEDING THE HYDRAULIC 

BRAKE SYSTEM" in chapter 3. 

EB702292 

ASSEMBLING AND INSTALLING THE REAR 
BRAKE MASTER CYLINDER 

1. Install: 

• copper washers (New) ® 

• brake hose (2 

• union bolt® 



30 Nm (3.0 m-kg) 



CAUTION: 

When installing the brake hose onto the 
brake master cylinder, make sure that the 
brake pipe touches the projection ® on 
the brake master cylinder. 



A WARNING 



Proper brake hose routing is essential to 
insure safe motorcycle operation. Refer 
to "CABLE ROUTING". 




2. Fill: 
• brake fluid reservoir 
(to the maximum level mark®) 



*q 



Recommended brake fluid 
DOT 4 



7-27 



FRONT AND REAR BRAKES 




A WARNING 



• Use only the designated brake fluid. 
Other brake fluids may cause the 
rubber seals to deteriorate, causing 
leakage and poor brake performance. 

• Refill with the same type of brake fluid 
that is already in the system. Mixing 
brake fluids may result in a harmful 
chemical reaction, leading to poor 
brake performance. 

• When refilling, be careful that water 
does not enter the reservoir. Water will 
significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock. 

CAUTION: 

Brake fluid may damage painted 
surfaces and plastic parts. Therefore, 
always clean up any spilt brake fluid 
immediately. 



3. Bleed: 
• brake system 
Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 




4. Check: 
• brake fluid level 
Below the minimum level mark (a) — ► Add 
the recommended brake fluid to the proper 
level. 

Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 



.Adjust: 

• brake pedal position (a) 
Refer to "ADJUSTING 
BRAKE" in chapter 3. 



THE REAR 




Brake pedal position (below 
the top of the rider footrest) 
36.6 mm 



6. Adjust: 
• rear brake light operation timing 
Referto "ADJUSTING THE REAR BRAKE 
LICHT SWITCH" in chapter 3. 



7-28 



FRONT AND REAR BRAKES 



FRONT BRAKE CALIPERS 





30 Nm(3.0 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the front brake calipers 




Remove the parts in the order listed. 




Drain the brake fluid 






1 


Union bolt 


1 - 


] Refer to "ASSEMBLING AND 


2 


Copper washer 


2 


INSTALLING THE FRONT BRAKE 


3 


Brake hose 


1 


CALIPERS" section. 


4 


Brake caliper assembly 


1 - 


For installation, reverse the removal 
procedure. 



7-29 



FRONT AND REAR BRAKES 





Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the front brake 




Disassembly the parts in the order listed. 




calipers 






© 


Clip 


2 - 




(2) 
<3> 

(D 


Pad pin 

Brake pad spring 

Brake pad 


1 
1 
2 


Refer to "REPLACING THE FRONT 
BRAKE PADS" section. 


© 


Bleed screw kit 


1 - 




<8> 


Brake caliper piston 
Dust seal 
Piston seal 


4 - 
4 

4 - 


" Refer to "DISASSEMBLING THE FRONT 
BRAKE CALIPER" section. 

For assembly, reverse the disassembly 
procedure. 



7-30 



FRONT AND REAR BRAKES 



REAR BRAKE CALIPER 




30 Nm(3.0 nvkg) 




^ 40 Nm(4.0 nrkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the rear brake caliper 




Remove the parts in the order listed. 




Drain the brake fluid 






1 
2 
3 

4 


Union bolt 
Copper washer 
Brake hose 
Rear brake caliper 


1 - 
2 
1 
1 - 


Refer to "ASSEMBLING AND 
INSTALLING THE REAR BRAKE 
CALIPER" section. 

For installation, revers the removal 
procedure. 



7-31 



FRONT AND REAR BRAKES 





Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the rear brake caliper 

Pad pin 
Pad spring 


2 - 
1 


Disassembly the parts in the order listed. 
Refer to "REPLACING THE REAR 


(3) 
<3> 


Brake pad assembly/shim 
Bleed screw kit 


2/2 

2 - 


BRAKE PAD" section. 


® 


Brake caliper piston 
Dust seal 
Piston seal 


2 - 
2 
2 - 


" Refer to "DISASSEMBLING THE REAR 


BRAKE CARIPER" section. 








For assembly, reverse the disassembly 
procedure. 



7-32 



FRONT AND REAR BRAKES 




EB702317 

DISASSEMBLING THE FRONT BRAKE 
CALIPERS 

The following procedure applies to both of the 
brake calipers. 

NOTE: 

Before disassembling either brake caliper, 
drain the brake fluid from the entire brake 
system. 




1. Remove: 

• union bolt® 

• copper washers < 

• brake hose ® 

NOTE: 



Put the end of the brake hose into a contain- 
er and pump out the brake fluid carefully. 




2. Remove: 

• brake caliper pistons ® 

• brake caliper piston seals 




a. Secure the right side brake caliper pis- 
tons with a piece of wood ® 

b. Blow compressed air into the brake hose 
joint opening ® to force out the left side 
pistons from the brake caliper. 

c. Remove the brake caliper piston seals. 

d. Repeat the previous steps to force out the 
right side pistons from the brake caliper. 



A WARNING 



• Never try to pry out the caliper pistons. 

• Do not remove the plugs @). 



7-33 



FRONT AND REAR BRAKES 




/ ( 


) \ 


© 












(2) ® 




EB702322 

DISASSEMBLING THE REAR BRAKE 
CALIPER 

NOTE: 



Before disassembling the brake caliper, 
drain the brake fluid from the entire brake 
system. 

1. Remove: 

• union bolt® 

• copper washers ® 

• brake hose ® 

NOTE: 

Put the end of the brake hose into a contain- 
er and pump out the brake fluid carefully. 



2. Remove: 

• brake caliper pistons ® 

• brake caliper piston seals < 



a. Secure the right side brake caliper piston 
with a piece of wood ® 

b. Blow compressed air into the brake hose 
joint opening © to force out the left side 
piston from the brake caliper. 



(§r\ 




^)w 


/® 








12230202 



A WARNING 



• Never try to pry out the brake caliper 
pistons. 

• Do not loosen the bolts (3). 

c. Remove the brake caliper piston seals. 

d. Repeat the previous steps to force out the 
right side piston from the brake caliper. 

EB702343 

CHECKING THE FRONT AND REAR BRAKE 
CALIPERS 



Recommended brake component 
replacement schedule 


Brake pads 


If necessary 


Piston seals 


Every two years 


Brake hoses 


Every four years 


Brake fluid 


Every two years and 
whenever the brake is 
disassembled. 



7-34 



FRONT AND REAR BRAKES 





B| 


^N 


Ipt 



Replace the 



1. Check: 

• brake caliper pistons ® 
Rust/scratches/wear - 
brake caliper. 

• brake caliper cylinders (D 
Scratches/wear -► Replace the brake cali- 
per. 

• brake calipers ® 
Cracks/damage -+ Replace. 

• brake fluid delivery passages 
(brake caliper body) 

Obstruction — ► Blow out with compressed 
air. 



A WARNING 



Whenever a brake caliper is disas- 
sembled, replace the brake caliper piston 
seals. 

El Front 
\E\ Rear 




2. Check: 
• brake caliper brackets ® 
Cracks/damage -► Replace. 

EB702374 

ASSEMBLING AND INSTALLING THE 
FRONT BRAKE CALIPERS 

The following procedure applies to both of the 
brake calipers. 



A WARNING 



Before installation, all internal brake 
components should be cleaned and lu- 
bricated with clean or new brake fluid. 
Never use solvents on internal brake 
components as they will cause the pis- 
ton seals to swell and distort. 
Whenever a brake caliper is disas- 
sembled, replace the brake caliper pis- 
ton seals. 




*q 



Recommended brake fluid 
DOT 4 



1. Install: 

• brake caliper® 
(temporarily) 

• copper washers (New) (2) 

• brake hose ® 

• union bolt® 



30 Nm (30 m-kg) 



A WARNING 



Proper brake hose routing is essential to 
insure safe motorcycle operation. Refer 
to "CABLE ROUTING ". 



7-35 



FRONT AND REAR BRAKES 





CAUTION: 

When installing the brake hose onto the 
brake caliper, make sure that the brake 
pipe a touches the projection (a) on the 
brake caliper. 

2. Remove: 

• brake caliper 

3. Install: 

• brake pads 

• brake spring 

• brake caliper pins 

• brake caliper clips 

• brake caliper 

• brake hose holder 

Refer to "REPLACING THE BRAKE 
PADS". 



V 



Brake caliper bolt 
40 Nm (40 nrkg) 



4. Fill: 
• brake master cylinder reservoir 
(with the specified amount of the recom- 
mended brake fluid) 



<o 



Recommended brake fluid 
DOT 4 



A WARNING 



• Use only the designated brake fluid. 
Other brake fluids may cause the rub- 
ber seals to deteriorate, causing leak- 
age and poor brake performance. 

• Refill with the same type of brake fluid 
that is already in the system. Mixing 
brake fluids may result in a harmful 
chemical reaction, leading to poor 
brake performance. 

• When refilling, be careful that water 
does not enter the reservoir. Water will 
significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock. 



CAUTION: 

Brake fluid may damage painted sur- 
faces and plastic parts. Therefore, al- 
ways clean up any spilt brake fluid im- 
mediately. 



7-36 



FRONT AND REAR BRAKES 




f 




1 


1 1 

1 x^ 1 


Y^i 


(1P*I^ L0WER 


. ■ s??*^- 


A£j 




€> 





5. Bleed: 

• brake system 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 

6. Check: 

• brake fluid level 

Below the minimum level mark (D ->• Add 

the recommended brake fluid to the proper 

level. 

Refer to "CHECKING THE BRAKE FLUID 

LEVEL" in chapter 3. 

7. Check: 

• brake lever operation 

Soft or spongy feeling -► Bleed the brake 

system. 

Refer to "BLEEDING THE HYDRAULIC 

BRAKE SYSTEM" in chapter 3. 



EB702378 

ASSEMBLING AND INSTALLING THE REAR 
BRAKE CALIPER 



/ C D \ 




















(^ 


Q 


:> 


^ 






A WARNING 



Before installation, all internal brake 
components should be cleaned and lu- 
bricated with clean or new brake fluid. 
Never use solvents on internal brake 
components as they will cause the pis- 
ton seals to swell and distort. 
Whenever a brake caliper is disas- 
sembled, replace the brake caliper pis- 
ton seals. 



•tt 



Recommended brake fluid 
DOT 4 



Install: 

• brake caliper® 
(temporarily) 

• copper washers (New) 

• brake hose (? 

• union bolt® 



30 Nm (3.0 m-kg) 



A WARNING 



Proper brake hose routing is essential to 
insure safe motorcycle operation. Refer 
to "CABLE ROUTING". 

CAUTION: 



When installing the brake hose onto the 
brake caliper, make sure that the brake 
pipe a slot the projection ® on the brake 
caliper. 



7-37 



FRONT AND REAR BRAKES 




Remove: 

• brake caliper 

Install: 

• brake pad spring 

• brake pads 

• brake pad pins 

• brake caliper 

• brake hose holder 
Refer to "REPLACING 
PADS". 



THE BRAKE 



x 



Brake caliper pad pin 
10Nm(1.0irrkg) 

Brake caliper bolt 
40 Nm (4.0 nvkg) 



Fill: 

• brake fluid reservoir 
(with the specified amount of the recom- 
mended brake fluid) 



<o 



Recommended brake fluid 
DOT 4 



A WARNING 



• Use only the designated brake fluid. 
Other brake fluids may cause the rub- 
ber seals to deteriorate, causing leak- 
age and poor brake performance. 

• Refill with the same type of brake fluid 
that is already in the system. Mixing 
brake fluids may result in a harmful 
chemical reaction, leading to poor 
brake performance. 

• When refilling, be careful that water 
does not enter the reservoir. Water will 
significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock. 

CAUTION: 

Brake fluid may damage painted sur- 
faces and plastic parts. Therefore, al- 
ways clean up any spilt brake fluid im- 
mediately. 



5. Bleed: 
• brake system 
Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 



7-38 



FRONT AND REAR BRAKES 





6. Check: 

• brake fluid level 

Below the minimum level mark (a) -► Add 

the recommended brake fluid to the proper 

level. 

Refer to "CHECKING THE BRAKE FLUID 

LEVEL" in chapter 3. 

7. Check: 

• brake pedal operation 

Soft or spongy feeling -► Bleed the brake 

system. 

Refer to "BLEEDING THE HYDRAULIC 

BRAKE SYSTEM" in chapter 3. 



7-39 



FRONT FORK 



FRONT FORK 




30 Nm (3.0 i 



"^ 7 Nm (0.7 rrrkg) 




30 Nm (3.0 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the front fork 




Remove the parts in the order listed. 




Front wheel 




Refer to "FRONT WHEEL AND BRAKE 
DISCS" section. 




Front brake calipers 




Refer to "FRONT AND REAR BRAKES" 
section. 


1 


Front fender 


1 




2 


Bolt (upper bracket) 


2 


NOTE: 


3 


Cap bolt 


2 


Loosen -, 


Refer to 
"REMOVING/ 


NOTE: 


4 
5 


Bolt (lower bracket) 

Front fork assembly (left/right) 


2 

1/1 


Loosen 


INSTALLING THE 
FRONT FORK 
LEGS" section. 


NOTE: 

Loosen - 


Refer to "REMOV 


NG/INSTALLING THE 








FRONT FORK LEGS" section. 








For installation, reverse the removal 








procedure. 



7-40 



FRONT FORK 




23 Nm (2.3 irrkg) 




30 Nm (3.0 m-kg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Disassembling the front fork 




Disassembly the parts in the order listed. 


© 


Cap bolt 






© 


O-ring 






® 


Spacer 






<3> 


Washer 






© 


Front fork spring 




Refer to "ASSEMBLING THE FRONT 


© 


Dust seal 




FORK LEGS" section. 


® 


Oil seal clip 






® 


Bolt 






® 


Gasket 






© 


Damper rod/rebound spring 


1/1- 




© 


Inner tube/Inner tube bushing 




i Refer to "DISASSEMBLING/ 


© 


Oil seal 




ASSEMBLING THE FRONT FORK 


© 


Washer 




LEGS" section. 



7-41 



FRONT FORK 




23 Nm (2.3 nvkg) 




30 Nm (3.0 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


© 


Outer tube bushing 


1 - 


i Refer to "ASSEMBLING THE FRONT 
J FORK LEGS" section. 


© 


Oil flow stopper 


1/1- 








For assembly, reverse the disassembly 








procedure. 



7-42 





^ 

kH^ 


fa 


g^r^m 


J^s- \£) 


lo 


%$(] 




— <D 


(LI 




~\X 






FRONT FORK 




EB703100 

REMOVING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 
1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

NOTE: 

Place the motorcycle on a suitable stand so 
that the front wheel is elevated. 

2. Loosen: 

• upper bracket pinch bolt ® 

• cap bolt @ 

• lower bracket pinch bolt ® 



A WARNING 



Before loosening the upper and lower 
bracket pinch bolts, support the front 
fork leg. 

3. Remove: 

• front fork leg 

EB703110 

DISASSEMBLING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 
1. Remove: 

• dust seal ® 

• oil seal clip® 

(with a flat-head screwdriver) 

CAUTION: 



Do not scratch the inner tube. 

2. Remove: 
• damper rod bolt 

NOTE: 



While holding the damper rod with the damp- 
er rod holder ® and T-handle ®, loosen the 
damper rod bolt. 




Damper rod holder 

90890-01460 
T-Handle 

90890-01326 



7-43 



FRONT FORK 





3. Remove: 
• inner tube 



a. Hold the front fork leg horizontally. 

b. Securely clamp the brake caliper bracket 
in a vise with soft jaws. 

c. Separate the inner tube from the outer 
tube by pulling the inner tube forcefully 
but carefully. 

CAUTION: 

• Excessive force will damage the oil seal 
and bushing. A damaged oil seal or 
bushing must be replaced. 

• Avoid bottoming the inner tube into the 
outer tube during the above procedure, 
as the oil flow stopper will be damaged. 




CHECKING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 
1. Check: 

• inner tube® 

• outer tube (2) 
Bends/damage/scratches -► Replace. 



A WARNING 



Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it. 



2. Measure: 
• spring free length (a) 
Over the specified limit 



Replace. 




Spring free length limit 
319 mm 



3. Check: 

• damper rod ® 
Damage/wear -+ Replace. 
Obstruction -► Blow out all of the oil pas- 
sages with compressed air. 

• oil flow stopper 
Damage/wear -► Replace. 

CAUTION: 



• The front fork leg has a built-in damper 
adjusting rod and a very sophisticated 
internal construction, which are partic- 
ularly sensitive to foreign material. 

• When disassembling and assembling 
the front fork leg, do not allow any for- 
eign material to enter the front fork. 



7-44 



FRONT FORK 






4. Check: 
• cap bolt O-ring 
Damage/wear - 



Replace. 



EB703700 

ASSEMBLING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 



A WARNING 



• Make sure that the oil levels in both 
front fork legs are equal. 

• Uneven oil levels can result in poor 
handling and a loss of stability. 

NOTE: 

• When assembling the front fork leg, be 
sure to replace the following parts: 
-inner tube bushing 

-outer tube bushing 
-oil seal 
-dust seal 

• Before assembling the front fork leg, make 
sure that all of the components are clean. 

1. Install: 

• damper rod ® 

CAUTION: 

Allow the damper rod to slide slowly 
down the inner tube until it protrudes 
from the bottom of the inner tube. Be 
careful not to damage the inner tube. 

2. Lubricate: 

• inner tube's outer surface 



*q 



Recommended lubricant 
Fork oil 10 W or equivalent 



3. Tighten: 

• damper rod bolt ® [\| 30 Nm < 30 m ' k 9> l £Jl 



NOTE: 

While holding the damper rod with the damp- 
er rod holder (2) and T-handle (3), tighten the 
damper rod bolt. 




Damper rod holder 

90890-01460 
T-handle 

90890-01326 



7-45 














ff) ^\ 

MP 

J ^^^~~^_____^ 12310403 












1 


i 


(a) 


f 


<£/ 



FRONT FORK 




4. Install: 
• outer tube bushing ® 
(with the fork seal driver weight @ and 
adapter ®) 




Fork seal driver weight (2) 

90890-01367 
Adapter (D 

90890-01381 



5. Install: 

• washer 

• oil seal ® 

(with the fork seal driver weight @ and 
adapter ®) 




Fork seal driver weight (5) 

90890-01367 
Adapter ® 

90890-01381 



CAUTION: 

Make sure that the numbered side of the 
oil seal, faces up. 

NOTE: 

• Before installing the oil seal, apply lithium 
soap base grease onto its lips. 

• Apply fork oil onto the outer surface of the 
inner tube. 

6. Install: 

• oil seal clip® 

NOTE: 

Adjust the oil seal clip so that it fits into the 
outer tube's groove. 

7. Install: 

• dust seal CD 

(with the fork seal driver weight) ® 



y- 



Fork seal driver weight 
90890-01367 



8.Fil 



front fork leg 

(with the specified amount of the recom- 
mended fork oil) 




Quantity (each front fork leg) 
0.475 L 



<o 



Yamaha fork and shock oil 
10 W or equivalent. 




Front fork leg oil level (a) (from 
the top of the inner tube, with 
the inner tube fully compressed 
and without the fork spring) 
121 mm 



7-46 




FRONT FORK 




NOTE: 

• While filling the front fork leg, keep it up- 
right. 

• After filling, slowly pump the front fork leg 
up and down to distribute the fork oil. 

9. Install: 

• spring ® 

• spring seat © 

• spacer ® 

• cap bolt 

NOTE: 

• Install the spring with the smaller pitch fac- 
ing up. 

• Before installing the cap bolt, apply grease 
onto the O-ring. 

• Temporarily tighten the cap bolt. 




EB703710 

INSTALLING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 

1. Install: * 

• front fork leg 

Temporarily tighten the upper and lower 
bracket pinch bolts. 

NOTE: 

Make sure that the inner fork tube is flush 
with the top of the handlebar holder. 

2. Tighten: 

• lower bracket pinch bolt ® 

• cap bolt @ 

• upper bracket pinch bolt ® 



V 



Lower bracket pinch bolt 

30 Nm (3.0 irrkg) 
Cap bolt 

23 Nm (2.3 irrkg) 
Upper bracket pinch bolt 

30 Nm (3.0 nvkg) 



A WARNING 



Make sure that the brake hoses are 
routed properly. 



7-47 



HANDLEBAR 



HANDLEBAR 




"^ 10Nm(1.0m-kg) 



23 Nm (2.3 irvkg) 




"^ 7 Nm (0.7 irvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the handle bar 




Remove the parts in the order listed. 


1 


Master cylinder bracket 






2 


Master cylinder assembly 






3 


Throttle cable housing cover 






4 


Handle bar switch (right) 






5 


Throttle cable housing 






6 


Throttle cable 






7 


Grip end 






8 


Grip assembly 






9 


Clutch cable 






10 


Clutch switch 






11 


Handle bar switch (left) 




Refer to "INSTALLING THE 
HANDLEBAR" section. 


12 


Starter cable 






13 


Grip end 




Refer to "INSTALLING THE 
HANDLEBAR" section. 



7-48 



HANDLEBAR 




*\" 10Nm(1.0nrkg) 



23 Nm (2.3 nvkg) 




"^ 7 Nm (0.7 nrkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


14 
15 
16 
17 


Grip (left) 

Clutch lever holder 
Upper handlebar holder 
Handle bar 


1 
1 

2 - 
1 - 


Refer to "REMOVING THE HANDLEBAR" 

section. 

-, Refer to "INSTALLING THE 
J HANDLEBAR" section. 

For installation, reverse the removal 

procedure. 



7-49 



HANDLEBAR 





EB704100 

REMOVING THE HANDLEBAR 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

2. Remove: 

• throttle cable housing (T) 

• throttle grip @ 

NOTE: 

While removing the throttle cable housing, 
pull back the rubber cover (3). 

3. Remove: 

• left handlebar grip ® 

NOTE: 

Blow compressed air between the handle- 
bar and the handlebar grip, and gradually 
push the grip off the handlebar. 



EB704400 

CHECKING THE HANDLEBAR 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



2. Check: 
• handlebar® 
Bends/cracks/damage 



A WARNING 



Replace. 



Do not attempt to straighten a bent han- 
dlebar as this may dangerously weaken 
it. 

3. Install: 
• handlebar grip 

a. Apply a light coat of rubber adhesive onto 
the left end of the handlebar. 

b. Slide the handlebar grip over the left end 
of the handlebar. 

c. Wipe off any excess rubber adhesive with 
a clean rag. 



A WARNING 



Do not touch the handlebar grip until the 
rubber adhesive has fully dried. 



7-50 



HANDLEBAR 






CD 



J] 



S^ /^VfE 


=i?m£^ 


® 




^^JjjM 


i3L 


y® 




^^^lX?C 


££§; 


iDv 




^\> 






>\I24 10603 




EB704701 

INSTALLING THE HANDLEBAR 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

2. Install: 
• handlebar® 
upper handlebar ho lders ' 

23 Nm (2.3 m-kg) 



CAUTION: 

• First, tighten the bolts on the front side 
(a) of the handlebar holder, then on the 
rear side. 

• turn the handlebar all the way to the left 
and right. If there is any contact with the 
fuel tank, adjust the handlebar posi- 
tion. 

NOTE: 

• The upper handlebar holders should be 
installed with the arrows facing forward. 

• Align the match marks ® on the handlebar 
with the upper surface of the lower handle- 
bar holders. 

3. Install: 

• clutch lever holder 

• handlebar grip® 

• left grip end (g) 

NOTE: 

There should be 1 .0 mm of clearance ® be- 
tween the handlebar grip and the left grip 
end. 

4. Install: 

• left handlebar switch ® 

NOTE: 

Align the projection (a) on the left handlebar 
switch with the hole ® in the handlebar. 



5. Install: 
• master cylinder bracket ® 

NOTE: 

Align the mating surfaces of the master cyl- 
inder bracket with the punch mark (right han- 
dlebar switch side) (a) on the handlebar. 



7-51 






/ ~T \ 


— (a) 




'AT 


^41 


— © 


-3 




---**5?--^**^^ 




14650602 



HANDLEBAR 




6. Install: 

• throttle grip ® 

• throttle cable housing (2) 

• throttle cables ® 

NOTE: 



Apply (D thin coat of lithium soap base 
grease onto the inside of the throttle grip and 
install it onto the handlebar. 

NOTE: 

• Align the projection (a) on the throttle cable 
housing with the hole @ in the handlebar. 



7. Install: 

• right grip end 

• right handlebar switch ® 



A WARNING 



Make sure that the throttle grip operates 
smoothly. 

NOTE: 

• Align the projection (a) on the right handle- 
bar switch with the hole ® in the handle- 
bar. 

8. Adjust: 

• clutch cable free play 

Refer to "ADJUSTING THE CLUTCH 
CABLE FREE PLAY" in chapter 3. 




Clutch cable free play (at the 
end of the clutch lever) 
10 ~ 15 mm 



9. Adjust: 
• throttle cable free play 
Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY" in chapter 3. 




Throttle cable free play (at the 
flange of the throttle grip) 
3-5 mm 



7-52 



STEERING HEAD 



STEERING HEAD 

LOWER BRACKET 




3 V 110 Nm (11.0 m«kg) 




Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the lower bracket 

Front cowling 




Remove the parts in the order listed. 
- Refer to "FRONT COWUNG/SEAT/ 
SIDE COVER/FUEL TANK" section in 




Fuel tank 
Front wheel 
Front fork 




-I chapter 3 

Refer to "FRONT WHEEL" section. 
Refer to "FRONT FORK" section. 


1 
2 
3 
4 
5 
6 
7 


Handle bar 

Main switch lead coupler 
Brake hose joint/cover 
Steering stem nut 
Upper bracket 
Lock washer 
Ring nut (upper) 
Rubber washer 1 


1/1 


Refer to "HANDLEBAR" section. 
NOTE: 

Disconnect the coupler. 


- Refer to "REMOVING THE LOWER 
BRACKET/INSTALLING THE STEER- 


8 


Ring nut (lower) 




J ING HEAD" section. 



7-53 



STEERING HEAD 




3 V 110 Nm (11.0 irrkg) 




Order 


Job name/Part name 


Q'ty 


Remarks 


9 


Lower bracket 






10 


Ball race cover 






11 
12 
13 


Ball bearing 
Rubber washer 1 
Ball bearing 




~ Refer to "INSTALLING THE STEERING 
HEAD" section. 

For installation, reverse the removal 
procedure. 



7-54 



STEERING HEAD 





EB705102 

REMOVING THE LOWER BRACKET 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

2. Remove: 

• upper ring nut 

• lower ring nut (D 

NOTE: 

Hold the lower ring nut with the exhaust and 
steering nut wrench (§), then remove the up- 
per ring nut with the ring nut wrench. 




Exhaust and steering nut 
wrench 
90890-01268 



A WARNING 



Securely support the lower bracket so 
that there is no danger of it falling. 




EB705401 

CHECKING THE STEERING HEAD 

LWash: 

• bearing balls 

• bearing races 



*C$ 



Recommended cleaning solvent 
Kerosine 



2. Check: 

• bearing ® 

• bearing race @ 
Damage/pitting 



Replace. 



3. Replace: 

• bearing balls 

• bearing races 



a. Remove the bearing races from the steer- 
ing head pipe with a long rod ® and ham- 
mer. 



7-55 



STEERING HEAD 





b. Remove the bearing race from the lower 
bracket with a floor chisel (§) and hammer. 

c. Install a new dust seal and new bearing 
races. 

CAUTION: 



If the bearing race is not installed proper- 
ly, the steering head pipe could be dam- 
aged. 

NOTE: 

• Always replace the bearing balls and bear- 
ing races as a set. 

• Whenever the steering head is disas- 
sembled, replace the dust seal. 

4. Check: 

• upper bracket 

• lower bracket 

(along with the steering stem) 
Bends/cracks/damage -► Replace. 



/4-M) 



EB705700 

INSTALLING THE STEERING HEAD 

1 . Lubricate: 

• upper bearing 

• lower bearing 

• bearing races 



Recommended lubricant 
Lithium soap base grease 



2. Install: 

• lower ring nut® 

• rubber washer @ 

• upper ring nut® 

• lock washer ® 

Refer to "CHECKING AND ADJUSTING 
THE STEERING HEAD" in chapter 3. 

3. Install: 

• upper bracket 

• steering stem nut 

NOTE: 

Temporarily tighten the steering stem nut. 

4. Install: 

• front fork legs 

Refer to "FRONT FORK". 

NOTE: 

Temporarily tighten the upper and lower 
bracket pinch bolts. 



7-56 



REAR SHOCK ABSORBER AND RELAY ARM 
REAR SHOCK ABSORBER AND RELAY ARM 





48 Nm (4.8 nvkg) 



^" 40 Nm (4.0 nvkg) 



48 Nm (4.8 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the rear shock absorber 




Remove the parts in the order listed. 




assembly and relay arm 








Side covers 




Refer to "FRONT COWLING/SEAT/ 
SIDE COVER/FUEL TANK" section in 
chapter 3 




Rear wheel 




Refer to "REAR WHEEL, BRAKE DISK 
AND REAR WHEEL SPROCKET" section. 


1 


Self-locking nut/washer 


1/1 




2 
3 


Bolt 

Self-locking nut/washer 

Bolt 

Self-locking nut/bolt 

Rear shock absorber assembly 


1 
1/1 


£ = 120 mm 


Refer to "REMOVING/ 
INSTALLING THE 


4 
5 
6 


1 

1/1 

1 


€ = 40 mm 


REAR SHOCK 
ABSORBER" section. 


7 


Self-locking nut 


1 





7-57 



REAR SHOCK ABSORBER AND RELAY ARM 





*\~ 48 Nm (4.8 nvkg) 



"^ 40 Nm (4.0 nvkg) 



48 Nm (4.8 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


8 


Bolt 


1 


£ = 80 mm 


9 


Relay arm 


1 




10 


Self-locking nut/washer 


1/1 




11 


Bolt 


1 


£ = 120 mm 


12 


Connecting plate 


2 




13 


Spacer 


1 




14 


Spacer 


2 




15 


Spacer 


1 




16 


Oil seal 


2 




17 


Bearing 


2 




18 


Bearing 


1 




19 


Bearing 


1 


For installation, reverse the removal 
procedure. 



7-58 



REAR SHOCK ABSORBER AND RELAY ARM 




HANDLING THE REAR SHOCK ABSORBER 



A WARNING 



This rear shock absorber contain highly 
compressed nitrogen gas. 
Before handling the rear shock absorber, 
read and make sure you understand the 
following information. The manufacturer 
cannot be held responsible for property 
damage or personal injury that may re- 
sult from improper handling of the rear 
shock absorber. 

• Do not tamper or attempt to open the 
rear shock absorber. 

• Do not subject the rear shock absorber 
to an open flame or any other source of 
high heat. High heat can cause an ex- 
plosion due to excessive gas pressure. 

• Do not deform or damage the rear 
shock absorber in any way. If the rear 
shock absorber, or both are damaged, 
damping performance will suffer. 




DISPOSING OF A REAR SHOCK ABSORBER 

a. Gas pressure must be released before 
disposing of a rear shock absorber. To re- 
lease the gas pressure, drill a 2 — 3 mm 
hole through the gas cylinder at a point 1 5 
— 20 mm from its end as shown ®. 



A WARNING 



Wear eye protection to prevent eye dam- 
age from released gas or metal chips. 



7-59 



REAR SHOCK ABSORBER AND RELAY ARM 




EB706204 

REMOVING THE REAR SHOCK ABSORBER 
ASSEMBLY 

1 . Stand the motorcycle on a level surface. 



A WARNING 




Securely support the motorcycle so that 
there is no danger of it falling over. 

NOTE: 

Place the motorcycle on a suitable stand so 
that the rear wheel is elevated. 

2. Disconnect: 
• battery leads 
(from the battery terminals) 

CAUTION: 



First, disconnect the negative lead (D, 
then the positive lead (2). 

3. Remove: 

• battery 

4. Remove: 

• side covers 

• connecting plate bolt ® 

• rear shock absorber assembly lower bolt 
@ 

NOTE: 

While removing the rear shock absorber as- 
sembly lower bolt, hold the swingarm so that 
it does not dropdown. 



5. Remove: 

• rear shock absorber assembly upper bolt 

® 

• rear shock absorber assembly 

NOTE: 

Raise the swingarm and then remove the 
rear shock absorber assembly from be- 
tween the swingarm and relay arm. 



7-60 



REAR SHOCK ABSORBER AND RELAY ARM 





CHECKING THE REAR SHOCK ABSORBER 
ASSEMBLY 

1. Check: 

• rear shock absorber rod 
Bends/damage -+ Replace the rear shock 
absorber assembly. 

• rear shock absorber 

oil leaks -► Replace the rear shock absorb- 
er assembly. 

• spring 

Damage/wear -► Replace the rear shock 
absorber assembly. 

• bushings 
Damage/wear -+ Replace. 

• dust seals 
Damage/wear -+ Replace. 

• bolts 
Bends/damage/wear -► Replace. 




EB706701 

INSTALLING THE REAR SHOCK 
ABSORBER ASSEMBLY 

1. Lubricate: 

• spacers 

• bearings 



Recommended lubricant 
Molybdenum disulfide grease 



2. Install: 
• rear shock absorber assembly 



X 



Rear shock absorber assembly 
upper nut 

40 Nm (4.0 nvkg) 
Rear shock absorber assembly 
lower nut 

40 Nm (4.0 nvkg) 
Relay-arm-to-frame-nut 

48 Nm (4.8 nvkg) 



NOTE: 

• When installing the rear shock absorber 
assembly, lift up the swingarm. 

• Install the connecting arm front bolt from 
the right. 

3. Connect: 

• battery leads 

(to the battery terminals) 

CAUTION: 

First, connect the positive lead (D, then 
the negative lead (2). 



7-61 



SWINGARM AND DRIVE CHAIN 



SWINGARM AND DRIVE CHAIN 




Hi* 




23 Nm (2.3 m-kg) 



"^ 7 Nm (0.7 nvkg) 



Order 


Job name/Part name 


Q'ty 


Remarks 




Removing the swingarm and drive 




Removing the parts in the order listed. 




chain 








Rear wheel 




Refer to "REAR WHEEL, BRAKE 
DISC AND REAR WHEEL SPROCKET" 
section. 




Rear shock absorber assembly 




i Refer to "REAR SHOCK ABSORBER 
J AND RELAY ARM" section. 




Relay arm 






Rear wheel sprocket 




Refer to "REMOVING THE ENGINE" 
section in chapter 4 


1 


Drive chain guard 


1 




2 


Brake hose holder 


2 




3 


Caliper bracket 






4 


Compression bar 






5 


Drive chain guide 






6 


Pivot shaft 






7 


Swingarm 






8 


Drive chain 






9 


Cover 


2 





7-62 



SWINGARM AND DRIVE CHAIN 




VI 115 Nm (11.5 m-kg) k— -<<®® 




23 Nm (2.3 m-kg) 



"^ 7 Nm (0.7 m-kg) 



Order 


Job name/Part name 


Q'ty 


Remarks 


10 
11 
12 


Spacer 
Bearing 
Washer 


1 
2 
2 


For installation, reverse the removal 
procedure. 



7-63 



SWINGARM AND DRIVE CHAIN 





NOTE: 

Before removing the drive sprocket, drive 
chain, and rear wheel, measure the drive 
chain slack and the length of a ten-link sec- 
tion of the drive chain. 



EB707111 

REMOVING THE SWINGARM 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

NOTE: 

Place the motorcycle on a suitable stand so 
that the rear wheel is elevated. 



2. Remove: 

• side covers 

• connecting plate bolt ® 

• rear shock absorber assembly lower bolt 

(2) 

NOTE: 

When removing the rear shock absorber as- 
sembly lower bolt, hold the swingarm so that 
it does not dropdown. 

3. Check: 

• swingarm side play 

• swingarm vertical movement 

a. Check the tightening torque of the pivot 
shaft nut. 



x 



Pivot shaft nut 
115 Nm (11.5 irrkg) 



b. Check the swingarm side play[A] by mov- 
ing the swingarm from side to side. 

c. If the swingarm side play is out of specifi- 
cation, check the spacers, bearings, 
washers, and dust covers. 




Swingarm side play (at the end 
of the swingarm) 
1 mm 



d. Check the swingarm vertical movement 
\E\ by moving the swingarm up and down. 
If swingarm vertical movement is not 
smooth or if there is binding, check the 
spacers, bearings, washers, and dust 
covers. 



7-64 



SWINGARM AND DRIVE CHAIN 





EB707400 

CHECKING THE SWINGARM 

1. Check: 
• swingarm 
Bends/cracks/damage -+ Replace. 



2. Check: 
• pivot shaft 
Roll the pivot shaft on a flat surface. 
Bends -+ Replace. 



A WARNING 



Do not attempt to straighten a bent pivot 
shaft. 

3. Wash: 

• pivot shaft 

• dust covers 

• spacer 

• washers 

• bearings 



® 



Recommended cleaning solvent 
Kerosine 




4. Check: 
• dust covers ® 




• spacer (§) 

• washers (3) 

• oil seals ® 
Damage/wear - 

• bearings © 
Damage/pitting - 


► Replace. 
-+ Replace 


5. Check: 

• connecting arms 

• relay arm (7) 
Damage/wear - 


® 

► Replace. 



7-65 



SWINGARM AND DRIVE CHAIN 



0©®(j)©(j)(Z)(§)(j)®(O) _ 



EM90±mmgimmmMammm 



BZ 




< - — " 



: : 



X=? 




12510201 




12510201 




EB707410 

CHECKING THE DRIVE CHAIN 

1. Measure: 
• ten-link section ® of the drive chain 
Out of specification -► Replace the drive 
chain. 




Ten-link drive chain section 
limit (maximum) 
150 mm 



NOTE: 

• While measuring the ten-link section, push 
down on the drive chain to increase its ten- 
sion. 

• Measure the length between drive chain 
roller ® and © as shown. 

• Perforin this measurement at two or three 
different places. 

2. Check: 

• drive chain 

Stiffness -► Clean and lubricate or replace. 

3. Clean: 

• drive chain 

a. Wipe the drive chain with a clean cloth. 

b. Put the drive chain in kerosine and re- 
move any remaining dirt. 

c. Remove the drive chain from the kerosine 
and completely dry it. 

CAUTION: 



This motorcycle has a drive chain with 
small rubber O-rings CD between the 
drive chain side plates. Never use high- 
pressure water or air, steam, gasoline, 
certain solvents (e.g., benzine), or a 
coarse brush to clean the drive chain. 
High-pressure methods could force dirt 
or water into the drive chain's internals, 
and solvents will deteriorate the O-rings. 
A coarse brush can also damage the O- 
rings. Therefore, use only kerosine to 
clean the drive chain. 

4. Check: 

• O-rings® 

Damage -► Replace the drive chain. 

• drive chain rollers © 
Damage/wear -► Replace the drive chain. 

• drive chain side plates ® 
Damage/wear -+ Replace the drive chain. 
Cracks -► Replace the drive chain. 



7-66 



SWINGARM AND DRIVE CHAIN 




5. Lubricate: 
• drive chain 



Recommended lubricant 
Engine oil or chain lubricant 
suitable for O-ring chains 




6. Check: 

• drive sprocket 

• rear wheel sprocket 

More than 1 /4 tooth ® wear -► Replace 

the drive chain sprockets as a set. 

Bent teeth -► Replace the drive chain 

sprockets as a set. 
© Correct 
® Drive chain roller 
® Drive chain sprocket 




EB707700 

INSTALLING THE SWINGARM 

1. Lubricate: 

• bearings 

• spacers 

• dust covers 

• pivot shaft 



Recommended lubricant 
Molybdenum disulfide grease 



2. Install: 

• drive chain 

• swingarm ® 

• relay arm @ 

• left connecting plate (3) 

• right connecting plate ® 



V 



Swingarm pivot shaft nut 
115 Nm (11.5 m-kg) 

Relay arm nut 
48 Nm (4.8 nrkg) 

Connecting plate nut 
48 Nm (4.8 nvkg) 



NOTE: 

Install the swingarm bolt ® from the left. 

3. Install: 

• rear shock absorber assembly 

• rear wheel 

Refer to "INSTALLING THE REAR 
SHOCK ABSORBER ASSEMBLY" and 
"REAR WHEEL". 



7-67 



SWINGARM AND DRIVE CHAIN 





4. Adjust: 
• drive chain slack 
Refer to "ADJUSTING THE DRIVE CHAIN 
SLACK" in chapter 3. 




Drive chain slack 
30 ~ 45 mm 



EB707710 

INSTALLING THE DRIVE CHAIN 

1 . Lubricate: 
• drive chain 



Recommended lubricant 
Engine oil or chain lubricant 
suitable for O-ring chains 



2. Install: 

• drive chain ® 

• drive sprocket (§) 

• washer (3) 

• drive sprocket nut ® [\ 



70 Nm (7.0 nvkg) 



NOTE: 

While applying the rear brake, tighten the 
drive sprocket nut. 

CAUTION: 



Never install a new drive chain onto worn 
drive chain sprockets; this will dramati- 
cally shorten the drive chain's life. 

5. Adjust: 
• drive chain slack 
Refer to "ADJUSTING THE DRIVE CHAIN 
SLACK" in chapter 3. 




Drive chain slack 
30 ~ 45 mm 



CAUTION: 

A drive chain that is too tight will over- 
load the engine and other vital parts, and 
one that is too loose can skip and dam- 
age the swingarm or cause an accident. 
Therefore, keep the drive chain slack 
within the specified limits. 



7-68 



CHAPTER 8 
ELECTRICAL 

ELECTRICAL COMPONENTS 8-1 

CIRCUIT DIAGRAM 8-2 

CHECKING SWITCHES 8-4 

CHECKING STEPS 8-4 

SWITCH CONNECTION AS SHOWN IN THIS MANUAL 8-4 

SWITCH POSITION AND TERMINAL CONNECTION 8-5 

IGNITION SYSTEM 8-6 

CIRCUIT DIAGRAM 8-6 

TROUBLESHOOTING 8-7 

ELECTRIC STARTING SYSTEM 8-13 

CIRCUIT DIAGRAM 8-13 

STARTING CIRCUIT OPERATION 8-14 

TROUBLESHOOTING 8-15 

STARTER MOTOR 8-22 

CHECKING THE STARTER MOTOR 8-23 

CHARGING SYSTEM 8-25 

CIRCUIT DIAGRAM 8-25 

TROUBLESHOOTING 8-26 

LIGHTING SYSTEM 8-29 

CIRCUIT DIAGRAM 8-29 

TROUBLESHOOTING 8-30 

LIGHTING SYSTEM CHECK 8-33 

SIGNAL SYSTEM 8-36 

CIRCUIT DIAGRAM 8-36 

TROUBLESHOOTING 8-38 

SIGNAL SYSTEM CHECK 8-40 

COOLING SYSTEM 8-51 

CIRCUIT DIAGRAM 8-51 

TROUBLESHOOTING 8-52 

FUEL PUMP SYSTEM 8-56 

CIRCUIT DIAGRAM 8-56 

FUEL PUMP CIRCUIT OPERATION 8-57 

TROUBLESHOOTING 8-58 

FUEL PUMP TEST 8-61 

SELF-DIAGNOSIS 8-62 

TROUBLESHOOTING 8-63 



ELEC 


+ 



ELEC 




+ 





ELECTRICAL COMPONENTS 



ELEC 


+ 



ELECTRICAL 



ELECTRICAL COMPONENTS 



© Main switch 
© Fuel sender 
® Rear brake switch 
© Battery 
® Ignitor unit 
® Starter relay 



© Starting circuit cut-off relay 

© Flasher relay 

© Sidestand switch 

© Neutral switch 

©Oil level gauge 

© Ignition coil 



© Rectifier/ Regulator 

© Thermo switch (warning light) 

© Thermo switch (fan motor) 

©Horn 

© Diode 




8-1 



CIRCUIT DIAGRAM 



CIRCUIT DIAGRAM 



ELEC 




+ 





(f 5 ) (f 3 ) r 



£Q 



© 


IB 


§ 


m 


| 


© 




i g 


X 
Q 

o 




T¥ 


z 
< 

2 




8-2 



CIRCUIT DIAGRAM 



ELEC 


+ 



® 
® 
® 
® 

® 
® 
® 



© 
© 
© 
© 
© 
© 
© 
© 
© 
© 
© 



A.C. magneto 

Rectifier regulator 

Main switch 

Battery 

Fuse (back up) 

Fuse (main) 

Starter relay 

Starter motor 

Starting circuit cut-off relay 

Fuel pump relay 

Ignitor unit 

Ignition coil 

Spark plug 

Pickup coil 

Throttle position sensor 

Neutral switch 

Speed sensor 

Fuel sender 

Thermo switch (warning light) 

Diode 

Fuel pump 

Sidestand switch 

Speedometer 

Tachometer 

Fuel meter 

Fuel level warning light 

Engine temperature warning light 

Neutral indicator light 

Oil level warning light 



© High beam indicator light 

©Turn indicator lights 

© Meter lights 

© Clutch switch 

© Oil level switch 

© Flasher relay 

©Horn 

© Pass switch 

© Dimmer switch 

© Horn switch 

©Turn switch 

© Front turn signal lights 

© Rear turn signal lights 

© Head light 

©Tail/Brake light 

©Auxiliary light 

© Fan motor 

© Thermo switch (fan motor) 

© Fuse (fan) 

© Fuse (head) 

© Rear brake switch 

© Fuse (signal) 

© Front brake switch 

© Lights switch 

© Engine stop switch 

© Starter switch 

© Fuse (ignition) 

© Alarm (option) 



NOTE: 

• Starter switch is closed while the button (switch) is pushed. 

• Sidestand switch is closed while the side stand is upped. 

• Clutch switch is closed while the clutch lever is pulled. 

• Brake switch is closed while the brake is applied. 



COLOR CODE 



B 


Black 


Y 


Yellow 


L/Y 


Blue/Yellow 


Br 


Brown 


W 


White 


L/W 


Blue/White 


Ch 


Chocolate 


B/L 


Black/Blue 


L/R 


Blue/Red 


Dg 


Dark green 


B/R 


Black/ Red 


R/B 


Red /Black 


G 


Green 


B/Y 


Black/Yellow 


R/Y 


Red/Yellow 


L 


Blue 


Br/L 


Brown/Blue 


R/W 


Red/White 


Lg 


Light green 


Br/W 


Brown/White 


Y/B 


Yellow/ Black 





Orange 


G/R 


Green /Red 


Y/R 


Yellow/White 


Sb 


Sky blue 


G/W 


Green/White 


W/B 


White/Black 


P 


Pink 


G/Y 


Green /Yellow 


W/G 


White/Green 


R 


Red 


L/B 


Blue/Black 







8-3 



CHECKING SWITCHES 




ELEC 




+ 





CHECKING SWITCHES 

CHECKING STEPS 

Using pocket tester, check switches for continu- 
ity between their terminals to determine whether 
they are correctly connected. 
Replace the switch component if any of the com- 
binations does not produce the correct reading. 



y- 



Pocket tester: 
90890-03112 



NOTE: 

• Turn the 



"ON", "OFF" 



switch to the 
positions several times. 
Adjust the pocket tester to correct "0" 
position before checking switches. 
Set the pocket tester selector to "~ 1 " £1 











\ Br 


R 




OFF 






ON O 


o 














Br 


^ 






bl 





SWITCH CONNECTION AS SHOWN IN THIS 
MANUAL 

This manual contains connection charts, like the 
one shown on the left, showing the terminal con- 
nections of switches (e.g. the main switch, han- 
dlebar switch, brake switch, lighting switch etc.) 

The column on the extreme left indicates the dif- 
ferent switch positions, the top line indicates the 
colors of the leads connected to the terminals on 
the switch. 



"O — O" indicates terminals between which 
there is continuity, i.e. a closed circuit, in the 
given switch position. 

In this chart: 

"Br and R" have continuity with the switch in the 

"ON" position. 



8-4 



CHECKING SWITCHES 



SWITCH POSITION AND TERMINAL CONNECTION 



ELEC 


+ 



Before checking a switch refer to the checking 
switches as shown in the left page and check 
for the correct terminal connections (closed 
circuit) according to the color combinations 
shown in the chart. 
Poor connection, fault -► Repair or replace. 




i Neutral r 






i switch i 




6\\ 




Sb 
B/R 













indicates coupler positions. 



8-5 



IGNITION SYSTEM 



ELEC 




+ 





IGNITION SYSTEM 

CIRCUIT DIAGRAM 



© 


hx.Vccii y 


%n 




i 


? !E 

1 * 

1 1 




i 


I 1 

— < 

± 2 




8-6 



IGNITION SYSTEM 



ELEC 


+ 



EB802010 

TROUBLESHOOTING 



IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): 



Procedure 

Check: 

1 . Fuses (main and ignition) 

2. Battery 

3. Spark plugs 

4. Ignition spark gap 

5. Spark plug cap resistance 

6. Ignition coil resistance 

7. Main switch 



8. Engine stop switch 

9. Neutral switch 
10-Sldestand switch 

11 . Diode (starting circuit cut-off relay) 

12. Pickup coil resistance 

13. Wiring connection (the entire ignition 
system) 



NOTE: 

• Remove the following part(s) before trouble- 
shooting: 

1) Seat 

2) Fuel tank 

3) Side cover (left) 

• Use the following special tool(s) for trouble- 
shooting. 




Ignition checker: 
90890-06754 

Pocket tester: 
90890-03112 



1 . Fuses (main and ignition) 



• Remove the fuses. 

• Connect the pocket tester (CI 
fuses. 

• Check the fuses for continuity. 



1) to the 



4 



CONTINUITY 



2. Battery 



Check the battery condition. 

Refer to "BATTERY INSPECTION" in 

CHAPTER 3. 



Open-circuit voltage: 
12.8 V or more at 20°C 



4 



CORRECT 



* 



NO CONTINUITY 



I 



Replace the fuses. 



INCORRECT 



1 



Clean the battery terminals. 
Recharge or replace the battery. 



8-7 



* 



4 



3. Spark plugs 



IGNITION SYSTEM 



Check the spark plug condition. 

Check the spark plug type. 

Check the spark plug gap. 

Refer to "SPARK LUG INSPECTION" in 

CHAPTER 3. 



ELEC 


+ 



Standard spark plug: 
CR9E, CR8E/U27ESR-N, U24ESR-N 
NGK/NIPPONDENSO 




Spark plug gap: 
0.7 ~ 0.8 mm 



INCORRECT 



& 



CORRECT 



4. Ignition spark gap 



• Disconnect the spark plug cap from the 
spark plug. 

• Connect the ignition checker ® as shown. 
(2) Spark plug cap 

• Turn the main switch to "ON". 




• Check the ignition spark gap (a) . 

• Crank the engine by pushing the starter 
switch, and increase the spark gap until a 
misfire occurs. 




s 



Minimum spark gap: 
6.0 mm 



4 



* 



OUT OF 

SPECIFICATION 
OR NO SPARK 



MEETS SPECIFICATION 



^ 



The ignition system is not faulty. 



8-8 



IGNITION SYSTEM 



* 



4 



5. Spark plug cap resistance 



• Remove the spark plug cap. 

• Connect the pocket tester (Q x 1k) to the 
spark plug cap. 



ELEC 


+ 




• Check if the spark plug cap has the speci- 
fied resistance. 



m 



Spark plug cap resistance: 
10kOat20°C 



& 



MEETS 
SPECIFICATION 



6. Ignition coil resistance 



• Disconnect the ignition coil connector from 
the wire harness. 

• Connect the pocket tester (£1 x 1) to the 
ignition coil. 



Check if the primary coil has the specified 
resistance. 



a* 



Primary coil resistance: 
1.87 ~ 2.53ftat20°C 



• Connect the pocket tester (£1 x 1k) to the 
ignition coil. 



• Check if the secondary coil has the speci- 
fied resistance. 



a* 



Secondary coil resistance: 
12 ~ 18knat20°C 



4 



BOTH MEET 
SPECIFICATION 



* 



OUT OF SPECIFICATION 



1 



Replace the spark plug cap. 



Tester (+) lead -► Red/Black terminal 
Tester (-) lead -► Orange (Gray) terminal 




Tester (+) lead -+ spark plug lead ® 
Tester (-) lead -+ spark plug lead (2) 




OUT OF SPECIFICATION 



\ 



Replace the ignition coil. 



8-9 



IGNITION SYSTEM 



* 



4 



7. Main switch 



Disconnect the main switch couplers from 

the wire harness. 

Check for continuity as follows: 

Red ® - Brown/Blue (2) 




Br/L R L/R L B L/Y 



ON 



OFF 



<?u 



o-o 



p 



o-o 



o-o 



Br/L 



T 



* 



CONTINUITY 



8. Engine stop switch 



Disconnect the right handlebar switch cou- 
pler from the wire harness. 
Check for continuity as follows: 
Red/White ® - Red/Black (2) 




"\^ 


R/V 


1/ R/W 




OFF 








ON 


O 


— O 








n=n. 


£ 


>p 




G/Y 


R/W 


R/W 


p 




L/V\i 


B 


Br 


■3 



4 



CONTINUITY 



9. Neutral switch 



Disconnect the neutral switch/lead from the 

neutral switch. 

Check for continuity as follows: 

Neutral switch terminal ®- Ground 



ELEC 




+ 





NO CONTINUITY 



1 



Replace the main switch. 



NO CONTINUITY 



1 



Replace the right handlebar switch. 



8-10 



IGNITION SYSTEM 



— ■ — T~~j2I^=ra! 


f^&&^Y/j9 




/P*\ 




I^SkI!? 




& 


Sb 

| 




/m 






i 



a 



CONTINUITY 



lO.Sidestand switch 



Disconnect the sidestand switch coupler 
from the wire harness. 
Check for continuity as follows: 
Black®- Black© 




J^i 



3 



4 



CONTINUITY 



11 . Diode (starting circuit cut-off relay unit) 



• Remove the relay unit from the wire har- 
ness. 

• Check for continuity as follows: 
Blue/Yellow© - Light green (2) 



©- 



Nfc 







RR/BL/W 



G/WB/^| 

B/Y B W/b| 



L/BL/Y Lg B/Y B W/B 

FT 



ELEC 


+ 



NO CONTINUITY 



I 



Replace the main switch. 



NO CONTINUITY 



1 



Replace the sidestand switch. 



8-11 



IGNITION SYSTEM 



Tester lead 
Tester © lead 



Blue/Yellow® 
Light green (2) 



Tester © lead 
Tester © lead 



Blue/Yellow® 
Light green (2) 



Continuity 



No 
Continuity 



4 



CORRECT 



12. Pickup coil resistance 



• Disconnect the pickup coil coupler from the 
wire harness. 

• Connect the pocket tester (£1 x 1 00) to the 
pickup coil terminal. 



Tester (+) lead -► Yellow terminal ® 
Tester (-) lead -+ Blue terminal (2) 



Check if the pickup coil has the specified re- 
sistance. 



m 



Pickup coil resistance: 
189 ~ 231 nat20°C 
(Yellow - Blue) 



4 



MEETS 
SPECIFICATIONS 



13. Wiring connection 



Check the connections of the entire ignition 

system. 

Refer to "CIRCUIT DIAGRAM". 



4 



CORRECT 



Replace the ignitor unit. 



ELEC 




+ 





INCORRECT 



1 



Replace the relay unit. 



OUT OF SPECIFICATION 



1 



Replace the pickup coil. 



POOR CONNECTION 



1 




Properly connect the ignition system. 



8-12 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



ELECTRIC STARTING SYSTEM 

CIRCUIT DIAGRAM 




8-13 



ELECTRIC STARTING SYSTEM 




■ ® 



© 



\© 



t 



® 



i i i i i i i -i i i i i i 




® 



i i i i r\ 



®A 



22C 



X X X X XV 



v® ©" 

1 I 



ELEC 


+ 



EB803010 

STARTING CIRCUIT OPERATION 

The starting circuit on this model consists of the 
starter motor, starter relay, and the starting cir- 
cuit cut-off relay. If the engine stop switch is on 
"RUN" and the main switch is on "ON" (both 
switches are closed), the starter motor can op- 
erate only if. 



The transmission is in neutral (the neutral 
switch is closed). 

or if 

The clutch lever is pulled to the handlebar 
(the clutch switch is closed) and the side- 
stand is up (the sidestand switch is closed). 



The starting circuit cut-off relay prevents the 
starter from operating when neither of these 
conditions have been met. In this instance, the 
starting circuit cut-off relay is open so current 
cannot reach the starter motor. 

When at least one of the above conditions have 
been met however, the starting circuit cut-off 
relay is closed, and the engine can be started by 
pressing the starter switch. 

WHEN THE TRANSMISSION IS IN 



33 NEUTRAL 



WHEN THE SIDESTAND IS UP AND 



^^ THE CLUTCH LEVER IS PULLED IN 

® Battery 

(2) Fuse (main) 

(3) Main switch 
(3) Fuse (ignition) 

(5) Engine stop switch 

(D Starting circuit cut-off relay 

(?) Diode 

(§) Clutch switch 

(D Sidestand switch 

© Neutral switch 

(Q) Start switch 

© Starter relay 

(T3 Starter motor 



8-14 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



EB803020 

TROUBLESHOOTING 



IF THE STARTER MOTOR FAILS TO OPERATE: 



Procedure 

Check: 

1 . Fuses (main and ignition) 

2. Battery 

3. Starter motor 

4. Starting circuit cut-off relay 

5. Starter relay 

6. Main switch 

7. Engine stop switch 



8. Neutral switch 

9. Sidestand switch 

10. Clutch switch 

11. Start switch 

12. Diode (starting circuit cut-off relay) 

13. Wiring connection (the entire starting 
system) 



NOTE: 

• Remove the following part(s) before trouble- 
shooting: 

1) Seat 

2) Fuel tank 

3) Side cover (left) 

• Use the following special tool(s) for trouble- 
shooting. 




Pocket tester: 
90890-03112 



1 . Fuses (main and ignition) 



• Remove the fuses. 

• Connect the pocket tester (CI 
fuses. 

• Check the fuses for continuity. 



1) to the 



4 



CONTINUITY 



2. Battery 



Check the battery condition. 

Refer to "BATTERY INSPECTION" in 

CHAPTER 3. 



Open-circuit voltage: 
12.8 V or more at 20°C 



4 



CORRECT 



* 



NO CONTINUITY 



I 



Replace the fuses. 



INCORRECT 



1 



Clean the battery terminals. 
Recharge or replace the battery. 



8-15 



ELECTRIC STARTING SYSTEM 



ELEC 




+ 





* 



4 



3. Starter motor 



Connect the battery positive terminal ®and 
starter motor cable ©using a jumper lead 

Check the operation of the starter motor. 



(r 



® 



I 



E 



?--.._ 



~®^3l 



J. 



© 



4 



MOVES 



4. Starting circuit cut-off relay (relay unit) 



• Remove the relay unit from the wire har- 
ness. 

• Connect the pocket tester (£2 ~ 1 ) and bat- 
tery (12 V) to the relay unit terminals. 



Battery (+) terminal -► 

Red/Black terminal® 
Battery (-) terminal -► 

Black/Yellow terminal® 



Tester (+) lead -► Blue/White terminal @ 
Tester (-) lead -+ Black terminal (4) 



* 



A WARNING 



• A wire that is used as a jumper lead must 
have the equivalent capacity or more as 
that of the battery lead, otherwise the 
jumper lead may burn. 

• This check is likely to reduce sparks, so be 
sure that no flammable gas or fluid is in the 
vicinity. 



DOES NOT MOVE 



a 



Repair or replace the starter motor. 




• Check the starting circuit cut-off relay for 
continuity. 



4 



CONTINUITY 



NO CONTINUITY 



I 



Replace the starting circuit cut-off relay. 



8-16 



ELECTRIC STARTING SYSTEM 



* 



& 



5. Starter relay 



Disconnect the relay unit coupler from the 
wire harness. 

Connect the pocket tester (Q ~ 1 ) and bat- 
tery (12 V) to the relay unit coupler termi- 
nals. 



Battery (+) terminal -► 

Red/White terminal® 
Battery (-) terminal -► 

Blue/White terminal® 



Tester (+) lead 
Tester (-) lead 



Red terminal (3) 
Black terminal (4) 



Check the starter relay for continuity. 



4 



CONTINUITY 



6. Main switch 



• Disconnect the main switch couplers from 
the wire harness. 

• Check for continuity as follows: 
Red ©-Brown /Blue© 




Br/L 



ON 



OFF 



% 



o-o 



EE 



L/R L 



OO 



IVY 



OO 



Br/L 



T 



A 



CONTINUITY 



* 



ELEC 


+ 



NO CONTINUITY 



I 



Replace the starter relay. 



NO CONTINUITY 



1 




Replace the main switch. 



8-17 



ELECTRIC STARTING SYSTEM 



* 



4 



7. Engine stop switch 



Disconnect the right handlebar switch cou- 
pler from the wire harness. 
Check for continuity as follows: 
Red/White ® - Red/White (2) 




OFF 



ON 



R/W 



a 



R/W 



■o 



G/Y 



L/W B 



JEpi 



Ei 3 



R/W 



R/W 



Br 



* 



CONTINUITY 



ELEC 




+ 





NO CONTINUITY 



1 



Replace the right handlebar switch. 



8. Neutral switch 



Disconnect the neutral switch/lead from the 

neutral switch. 

Check for continuity as follows: 

Neutral switch terminal ®- Ground 





4 



CONTINUITY 



* 



NO CONTINUITY 



1 



Replace the neutral switch. 



8-18 



ELECTRIC STARTING SYSTEM 



* 



& 



9.Sidestand switch 



Disconnect the sidestand switch coupler 
from the wire harness. 
Check for continuity as follows: 
Black® - Black© 








i 




n=n 




B 


*A 



a 



CONTINUITY 



ELEC 


+ 



NO CONTINUITY 



l 



Replace the sidestand switch. 



10. Clutch switch 



Disconnect the clutch switch coupler from 
the wire harness. 
Check for continuity as follows: 
Black/Yellow© - Blue/Yellow© 



G> 



5 



O 



J5L 



B/Y 



L/Y 



I 



4 



CONTINUITY 



* 



NO CONTINUITY 



1 



Replace the clutch switch. 



8-19 



ELECTRIC STARTING SYSTEM 



* 



4 



11. Start switch 



Disconnect the right handlebar switch cou- 
pler from the wire harness. 
Check for continuity as follows: 
Blue/White® -Black© 




OFF 



ON 



L/W 



(DJg 



ss 



G/Y 



L/W 



R/W 



R/W 



I 



Br 



* 



CONTINUITY 



12. Diode (starting circuit cut-off relay) 



• Remove the relay unit from the wire har- 
ness. 

• Check for continuity as follows: 
Black/ Yellow® - Light green© 



2. 









-f 






^~ 






X 




-J) 



/,D 


R/B 


L/W 




G/W 


\ 


[L/R 




B/Rl 


|l_/B 


IVY 


Lg 


B/Y 


B 


W/B 






P 


d 







Tester (+) lead 
Tester (-) lead 



^Black/Yellow ® 
y Light green © 



Tester (+) lead -+ Light green ® 
Tester (-) lead -+ Black/ Yellow © 



Continuity 



No 
Continuity 



4 



CORRECT 



* 



ELEC 




+ 





NO CONTINUITY 



1 



Replace the right handlebar switch. 



INCORRECT 



1 



Replace the relay unit. 



8-20 



* 



& 



13. Wiring connection 



ELECTRIC STARTING SYSTEM 



ELEC 


+ 



Check the connections of the entire starting 

system. 

Refer to "CIRCUIT DIAGRAM". 



POOR CONNECTION 



1 



Properly connect the starting system. 



8-21 



ELECTRIC STARTING SYSTEM 



ELEC 




+ 





EB803030 

STARTER MOTOR 




Order 


Job name/Part name 


Q'ty 


Remarks 




Starter motor removal 




Remove the parts in order. 




1 


Starter motor 


1 






2 


Starter motor lead 


1 


Reverse the removal procedure for 
installation. 






Starter motor disassembly 




Disassembly the parts in order. 




® 


Front bracket 


1 






@ 


Washers 


1 






® 


Rear bracket 


2 






(3) 


Shims 


1 






® 


Brush holder/Brush 


1/1 






® 


Armature ass'y 


1 


Reverse the disassembly procedure 
assembly. 


for 



8-22 



ELECTRIC STARTING SYSTEM 




ELEC 


+ 



CHECKING THE STARTER MOTOR 

1. Measure: 
• Brush length (a) 
Out of specification -► Replace. 




Brush length wear limit: 
4 mm 



2. Measure: 
• Brush spring force 
Fatigue/out of specification 
a set. 



Replace as 




Brush spring force: 
780 ~ 1,020 g 



3. Inspect: 

• Commutator 

Dirty -► Clean it with #600 grit sandpaper. 

4. Inspect: 

• Armature coil resistances (insulation/con- 
tinuity) 

Defects -+ Replace the starter motor. 

Inspection steps: 

• Connect the pocket tester for the continuity 
® and insulation @ checks. 

• Measure the armature coil resistances. 



m 



Armature coil continuity 
resistance®: 

0.0015 ~ 0.0025 £1 at 20° C 
Armature coil insulation 
resistance®: 

More than 1 Mftat20°C 



• If the resistance is incorrect, replace the 
starter motor. 



8-23 



ELECTRIC STARTING SYSTEM 




ELEC 




+ 





. Measure: 
• Commutator diameter ® 

Out of specification -► Replace the starter 

motor. 




Commutator wear limit: 
27 mm 



6. Measure: 
• Mica undercut® 
Out of specification -► Scrape the mica to 
the proper measurement using a hacksaw 
blade which has been grounded to fit the 
commutator. 




Mica undercut: 
0,7 mm 



NOTE: 

The mica insulation of the commutator must 
be undercut to ensure proper operation of 
the commutator. 



8-24 



CHARGING SYSTEM 



ELEC 


+ 



CHARGING SYSTEM 

CIRCUIT DIAGRAM 







8-25 



CHARGING SYSTEM 



EB803020 

TROUBLESHOOTING 



ELEC 




+ 





IF THE BATTERY IS NOT CHARGED: 



Procedure 

Check: 
LFuse (main) 

2. Battery 

3. Charging voltage 



4. Stator coil resistance 

5. Wiring connections (the entire charging 
system) 



NOTE: 

• Remove the following part(s) before trouble- 
shooting: 

1) Seat 

2) Side cover (left) 

• Use the following special tool(s) for trouble- 
shooting. 



y- 



Engine tachometer: 

90890-03113 
Pocket tester: 
90890-03112 



1. Fuses (main) 



• Remove the fuses. 

• Connect the pocket tester (£1 
fuses. 

• Check the fuses for continuity. 



1) to the 



4 



CONTINUITY 



2. Battery 



Check the battery condition. 

Refer to "BATTERY INSPECTION" in 

CHAPTER 3. 



Open-circuit voltage: 
12.8 V or more at 20° C 



4 



CORRECT 



* 



NO CONTINUITY 



1 



Replace the fuses. 



INCORRECT 



1 



Clean the battery terminals. 
Recharge or replace the battery. 



8-26 



CHARGING SYSTEM 



* 



& 



3. Charging voltage 



• Connect the engine tachometer to the spark 
plug lead. 

• Connect the pocket tester (DC 20 V) to the 
battery. 



Tester (+) lead 
Tester (-) lead 



Battery (+) terminal 
Battery (-) terminal 



• Measure the battery terminal voltage. 

• Start the engine and accelerate to about 
5,000 r/min. 

• Check the terminal voltage. 



m 



Charging voltage = measured 
voltage-terminal voltage: 
0.2 ~ 2.5 V up 



NOTE: 

Use a fully charged battery. 



i 



OUT OF 
SPECIFICATION 



4. Stator coil resistance 



• Remove the generator cover. 

• Connect the pocket tester (H x 1) to the 
stator coils. 



Tester (+) lead -► White terminal ® 
Tester (-) lead — ► White terminal (2) 



Tester (+) lead -► White terminal ® 
Tester (-) lead -► White terminal (3) 



Measure the stator coil resistance. 



m 



Stator coil resistance: 
0.36 ~ 0.44 a at 20° C 



ft 



BOTH MEET 
SPECIFICATION 



* 



ELEC 


+ 




MEETS SPECIFICATION 



The charging circuit is not faulty. 




OUT OF SPECIFICATION 



1 



Replace the stator coil-|assembly. 



8-27 



CHARGING SYSTEM 



ELEC 


+ 



* 



4 



5. Wiring connections 



Check the connections of the entire charg- 
ing system. 
Refer to "CIRCUIT DIAGRAM". 



POOR CONNECTION 



a 



a- 



CORRECT 



Properly connect the charging system. 



Replace the rectifier/regulator. 



8-28 



LIGHTING SYSTEM 



ELEC 


+ 



LIGHTING SYSTEM 

CIRCUIT DIAGRAM 



O CT 






I gig ^S." 

CO -^ 0> (t, ^ ^ O) 

Q.QIF<L J 




8-29 



LIGHTING SYSTEM 



ELEC 




+ 





EB803020 

TROUBLESHOOTING 



IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHTS, TAILLIGHT, AUXILIARY LIGHT 
AND/OR METER LIGHT FAIL TO COME ON: 



Procedure 

Check: 

1 . Fuses (main and head) 

2. Battery 

3. Main switch 

4. Lights switch (for Europe) 



5. Dimmer switch 

6. Pass switch (for Europe and Australia) 

7. Wiring connections (the entire lighting 
system) 



NOTE: 

• Remove the following part(s) before trouble- 
shooting: 

1) Seat 

2) Fuel tank 

3) Side cover (left) 

4) Front cowling assembly 

• Use the following special tool(s) for trouble- 
shooting. 




Pocket tester: 
90890-03112 



1 . Fuses (main and head) 



• Remove the fuses. 

• Connect the pocket tester (£1 
fuses. 

• Check the fuses for continuity. 



1) to the 



4 



CONTINUITY 



2. Battery 



Check the battery condition. 

Refer to "BATTERY INSPECTION" in 

CHAPTER 3. 



Open-circuit voltage: 
12.8 V or more at 20 °C 



4 



CORRECT 



* 



NO CONTINUITY 



I 



Replace the fuses. 



INCORRECT 



1 



Clean the battery terminals. 
Recharge or replace the battery. 



8-30 



LIGHTING SYSTEM 



* 



4 



3. Main switch 



Disconnect the main switch couplers from 

the wire harness. 

Check for continuity as follows: 

Red ® - Brown/Blue (2) 

Blue/Red® -Blue® 




ON 



OFF 



Br/L 



GMT 



oo 



L/R 



OO 



oo 



L/Y 



oo 



d^-E 



Br/L 



<3f 



IVY 



L/B 



L/R 



3 

XD 



a 



CONTINUITY 



4. Lights switch 



• Disconnect the right handlebar switch cou- 
pler from the wire harness. 

• Turn the lights switch to "ON" or TO". 

• Check for continuity as follows: 
Red/Yellow® -Blue® 

• Turn the lights switch to "ON". 

• Check for continuity as follows: 
Red/Yellow® -Blued) 
Red/Yellow® - Blue/Black (2) 




^\^ 


R/Y 


L 


L/B 


OFF 








PO 


£-1 


-0 




ON 




-o- 


-0 




T 


lr 


^l 






L/B 


L 


R/Y £ 



(3) (2) O 



ft 



CONTINUITY 



* 



ELEC 


+ 



NO CONTINUITY 



1 



Replace the main switch. 



NO CONTINUITY 



1 



The lights switch is faulty. Replace the right 
handlebar switch. 



8-31 



LIGHTING SYSTEM 



* 



4 



5. Dimmer switch 



• Disconnect the left handlebar switch cou- 
plers from the wire harness. 

• Turn the dimmer switch to "HI". 

• Check for continuity as follows: 
Blue/Black® -Yellow® 



4 



CONTINUITY 



6. Pass switch 



• Disconnect the left handlebar switch cou- 
pler from the wire harness. 

• Turn the pass switch to "ON". 

• Check for continuity as follows: 
Red/ Yellow®- Yellow® 




OFF 



ON 



R/Y 



-B. 



Wt 



Br/W 



L/B 



w 

g/1 



*"\X 



m 



Dg 



Ch 



L/Y 



B/Y 



& 



CONTINUITY 



7. Wiring connections 



Check the connections of the entire lighting 

system. 

Refer to "CIRCUIT DIAGRAM". 



4 



CORRECT 



Check the condition of each of the lighting 

system's circuits. 

Refer to "LIGHTING SYSTEM CHECK". 



ELEC 


+ 




NO CONTINUITY 



I 



The dimmer switch is faulty. 
Replace the left handlebar switch. 



NO CONTINUITY 



a 



The pass switch is faulty. Replace the left 
handlebar switch. 



POOR CONNECTION 



\ 



Properly connect the lighting system. 



8-32 



LIGHTING SYSTEM 



ELEC 


+ 



EB805020 

LIGHTING SYSTEM CHECK 

1 . If the headlight and the high beam indicator 
light fail to come on: 



1 . Bulb and bulb socket. 



Check the bulb and bulb socket for continu- 
ity. 



a 



CONTINUITY 



2. Voltage 



• Connect the pocket tester (DC 20 V) to the 
headlight and high beam indicator light cou- 
plers. 



[A] When the dimmer switch is on "LO". 
\E\ When the dimmer switch is ON "HI". 



Headlight connector 



DC20V 



E 




•JbTyD b 



s 




|b/lD b 



0^(3) ® ® 



H 



NO CONTINUITY 



1 



Replace the bulb and/or bulb socket. 



Headlight: 
Tester (+) lead -+ 
Black/ Yellow lead ® or 
Black/Blue lead (2) 
Tester (-) lead -+ Black lead (3) 
High beam indicator light: 
Tester (+) lead -► Yellow lead (4) 
Tester (-) lead -+ Black lead (5) 



S Meter connector 



'UYR/G W 



Ch Sb Y B/RY/B 



7 




G/WG/R 



^ 



• Turn the main switch to "ON". 

• Turn the light switch to "ON". 

• Turn the dimmer switch to "LO" or "HI". 

• Check the voltage (12 V) of the "Black/Yel- 
low", "Black/Blue" and "Yellow" leads on the 
bulb socket connector. 



a 



MEETS 
SPECIFICATION 



This circuit is not faulty. 



OUT OF SPECIFICATION 



I 



The wiring circuit from the main switch to the 
bulb socket connector is faulty, repair it. 



8-33 



LIGHTING SYSTEM 



2. If the meter light fails to come on: 



1 . Bulb and bulb socket 



Check the bulb and bulb socket for continu- 
ity. 



4 



CONTINUITY 



2. Voltage 



Connect the pocket tester (20 V) to the bulb 
socket coupler. 



Tester (+) lead -► Blue terminal ® 
Tester (-) lead -+ Black terminal (2) 



ELEC 




+ 





NO CONTINUITY 



1 



Replace the bulb and/or bulb socket. 




• Turn the main switch to "ON". 

• Turn the light switch to "ON" or "PO". 

• Check the voltage (12 V) of the "blue" lead 
on the bulb socket connector. 



4 



MEETS 
SPECIFICATION 



The circuit is not faulty. 



OUT OF SPECIFICATION 



1 



The wiring circuit from the main switch to the 
bulb socket connector is faulty, repair it. 



3. If the taillight fails to come on: 



1 . Bulb and bulb socket 



Check the bulb and bulb socket for continu- 
ity. 



4 



CONTINUITY 



2. Voltage 



Connect the pocket tester (DC 20 V) to the 
bulb socket connector. 



Tester (+) lead -t- Blue terminal © 
Tester (-) lead -► Black terminal (2) 



NO CONTINUITY 



1 



Replace the bulb and/or bulb socket. 





8-34 



LIGHTING SYSTEM 



• Turn the main switch to "ON". 

• Turn the lights switch to "ON" or "PO". 

• Check the voltage (12 V) of the "Blue" lead 
on the bulb socket connector. 



4 



MEETS 
SPECIFICATION 



This circuit is not faulty. 



ELEC 


+ 



OUT OF SPECIFICATION 



1 



The wiring circuit from the main switch to the 
bulb socket connector is faulty, repair it. 



4. If the auxiliary light fails to come on: 



1 . Bulb and bulb socket 



Check the bulb and bulb socket for continu- 
ity. 



a 



CONTINUITY 



2. Voltage 



Connect the pocket tester (DC 20 V) to the 
bulb socket connector. 



Tester (+) lead -► Blue/Red terminal ® 
Tester (-) lead -► Black terminal (2) 



NO CONTINUITY 



i 



Replace the bulb and/or bulb socket. 




• Turn the main switch is "ON". 

• Turn the lights switch to "ON" or "PO". 

• Check the voltage (12 V) of the "Blue/Red" 
lead on the bulb socket connector. 



a 



MEETS 
SPECIFICATION 



This circuit is not faulty. 



OUT OF SPECIFICATION 



l 



The wiring circuit from the main switch to the 
bulb socket connector is faulty, repair it. 



8-35 



SIGNAL SYSTEM 



ELEC 


+ 



SIGNAL SYSTEM 

CIRCUIT DIAGRAM 



© © ,— , 
f* f* r* f* IB 



© 




m ! 

i 


© 


1 


s < 

i I 

3. < 

1 ° 


1 


1 

1 1 

1 z 
— < 




8-36 



SIGNAL SYSTEM 



ELEC 


+ 



(3) Main switch 

Battery 

(6) Fuse (main) 

© Neutral switch 

© Fuel sender 

© Diode 

© Fuel meter 

@ Fuel level warning light 

© Neutral indicator light 

© Oil level warning light 

(5j)Turn indicator light 

@ Oil level switch 

@ Flasher relay 

@Horn 

© Horn switch 

©Turn switch 

© Front turn signal light 

© Rear turn signal light 

@ Tail/brake light 

© Rear brake switch 

© Fuse (signal) 

© Front brake switch 

65) Start switch 



8-37 



SIGNAL SYSTEM 



ELEC 




+ 





TROUBLESHOOTING 



IF THE TURN SIGNAL LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON: 
IF THE HORN FAILS TO SOUND: 



Procedure 

Check: 

1 . Fuses (main and signal) 

2. Battery 

3. Main switch 

4. Wiring connection (the entire signal system) 



NOTE: 

• Remove the following part(s) before trouble- 
shooting: 

1) Seat 

2) Fuel tank 

3) Side covers (left and right) 

4) Front cowling assembly 

• Use the following special tool8s) for trouble- 
shooting. 




Pocket tester: 
90890-03112 



1 . Fuses (main and signal) 



• Remove the fuses. 

• Connect the pocket tester (£1 x 1) to the 
fuses. 

• Check the fuses for continuity. 



4 



CONTINUITY 



2. Battery 



Check the battery condition. 

Refer to "BATTERY INSPECTION" in 

CHAPTER 3. 



Open-circuit voltage: 
12.8 V or more at 20 °C 



4 



CORRECT 



* 



NO CONTINUITY 



I 



Replace the fuses. 



INCORRECT 



1 



Clean the battery terminals. 
Recharge or replace the battery. 



8-38 



SIGNAL SYSTEM 



* 



& 



3. Main switch 



Disconnect the main switch coupler from 
the wire harness. 
Check for continuity as follows: 
Red® - Brown/Blue(2) 




Br/L 



ON 



OFF 



% 



oo 



m 



L/R 



OO 



IVY 



OO 



Br/L 



S 



ft 



CONTINUITY 



4. Wiring connections 



• Check the connections of the entire signal 
system. 
Refer to "CIRCUIT DIAGRAM". 



4 



CORRECT 



Check the condition of each of the signal sys- 
tem's circuits. 
Refer to "SIGNAL SYSTEM CHECK". 



ELEC 


+ 



NO CONTINUITY 



1 



Replace the main switch. 



POOR CONNECTION 



I 



Properly connect the signal system. 



8-39 



SIGNAL SYSTEM 



EB806020 

SIGNAL SYSTEM CHECK 

1 . If the horn fails to sound: 



1 . Horn switch 



• Disconnect the left handlebar switch cou- 
pler from the wire harness. 

• Disconnect the "Black/White" lead at the 
horn terminal. 

• Check for continuity as follows: 
Pink®- Black (2) 



4 



CONTINUITY 



2. Voltage 



• Connect the pocket tester (DC 20 V) to the 
horn lead. 



Tester (+) lead 
Tester (-) lead 



Brown lead ® 
Frame ground 



• Turn the main switch to "ON". 

• Check the voltage ( 1 2 V) of the "Brown" lead 
at the horn terminal. 



4 



MEETS 
SPECIFICATION 



3. Horn 



• Disconnect the "Pink" lead at the horn termi- 
nal. 

• Connect a jumper lead ® to the horn termi- 
nal and ground the jumper lead. 

• Turn the main switch to "ON". 



ELEC 




+ 






NO CONTINUITY 



I 



Replace the left handlebar switch. 



T 


r 


Br 

l_ 


p 

i 




' 






J< 


o\ 


- °l 




(xf , 






{Q 





OUT OF SPECIFICATION 



\ 



The wiring circuit from the main switch to the 
horn terminal is faulty, repair it. 



8-40 



SIGNAL SYSTEM 



T 




Br 














^© 




o 


(o j 






o) J 





4 



HORN DOES 
NOT SOUND 



4. Voltage 



• Connect the pocket tester (DC 20 V) to the 
horn at the "Pink" terminal. 



Tester (+) lead -► Brown lead ® 
Tester (-) lead -+ Pink 



• Turn the main switch to "ON". 

• Check the voltage (12 V) of the "Pink" lead 
at the horn terminal. 



4 



MEETS 
SPECIFICATION 



Adjust or replace the horn. 



ELEC 


+ 



HORN SOUNDS 



ly 



The horn is not faulty. 




OUT OF SPECIFICATION 



1 



Replace the horn. 



2. If the brake light fails to come on: 



1 . Bulb and bulb socket 



Check the bulb and bulb socket for continu- 
ity. 



4 



CONTINUITY 



* 



NO CONTINUITY 



1 



Replace the bulb and/or bulb socket. 



8-41 



SIGNAL SYSTEM 



* 



4 



2. Brake switch 



• Disconnect the front brake switch leads. 

• Disconnect the rear brake switch coupler 
from the wire harness. 

• Check for continuity as follows: 
Brown ® - Green/Yellow (2) 
Black® -Black® 



w 




WW 

,0,0 



T 



Br 
-I 



[A] Front brake switch 
\E\ Rear brake switch 



4 



CONTINUITY 



3. Voltage 



Connect the pocket tester (DC 20 V) to the 
bulb socket connector. 



Tester (+) lead 
Tester (-) lead 



Yellow terminal ® 
Black terminal (2) 



• Turn the main switch to "ON". 

• The brake lever is pulled in or the brake ped- 
al is pressed down. 

• Check the voltage (1 2 V) of the "Yellow" lead 
on the bulb socket connector. 



4 



MEETS 
SPECIFICATION 



This circuit is not faulty. 



ELEC 




+ 






OUT OF SPECIFICATION 



1 



The wiring circuit from the main switch to the 
bulb socket connector is faulty, repair it. 



8-42 



SIGNAL SYSTEM 



ELEC 


+ 



3. If the turn signal light and/or turn indicator 
light fails to blink: 



1 . Bulb and bulb socket 



Check the bulb and bulb socket for continu- 
ity. 



4 



CONTINUITY 



2. Turn switch 



Disconnect the left handlebar switch cou- 
plers from the wire harness. 
Check for continuity as follows: 
Brown/White ® - Chocolate (2) 
Brown/White ® - Dark green (3) 




CONTINUITY 



3. Voltage 



Connect the pocket tester (DC 20 V) to the 
flasher relay coupler. 



Tester (+) lead 
Tester (-) lead 



Brown terminal ® 
Frame ground 



• Turn the main switch to "ON". 

• Check the voltage (12 V) of the "Brown" ® 
lead at the flasher relay terminal. 



& 



MEETS 
SPECIFICATION 



* 



NO CONTINUITY 



l 



Replace the bulb and/or bulb socket. 



NO CONTINUITY 



1 



Replace the left handlebar switch. 




OUT OF SPECIFICATION 



1 



The wiring circuit from the main switch to the 
flasher relay connector is faulty, repair it. 



8-43 



SIGNAL SYSTEM 



* 



4 



4. Voltage 



Connect the pocket tester (DC 20 V) to the 
flasher relay coupler. 



Tester (+) lead -► 

Brown/White terminal® 
Tester (-) lead -+ Frame ground 



• Turn the main switch to "ON". 

• Turn the turn switch to "L" or "R". 
•Check the voltage (12 V) on the 

"Brown/White" ® lead at the flasher relay 
terminal. 



4 



MEETS 
SPECIFICATION 



5. Voltage 



• Connect the pocket tester (DC 20 V) to the 
bulb socket connector. 



H Flasher light 

\B\ Turn indicator light 



At the flasher light (left): 
Tester (+) lead -+ Chocolate lead ® 
Tester (-) lead -► Frame ground 



At the flasher light (right): 
Tester (+) lead -► Dark green lead (2) 
Tester (-) lead -+ Frame ground 



ELEC 




+ 






OUT OF SPECIFICATION 



1 



The flasher relay is faulty, replace it. 



IT 



TT 

Ch Dg 




fL/Y|R/G| W [XIXIXDKI Br I L | B^ 



£ 



Ch Sb Y B/RY/BX p 9 G/WG/R G 



• Turn the main switch to "ON". 

• Turn the turn switch to "L" or "R". 

• Check the voltage (1 2 V) of the "Chocolate" 
lead or "Dark green" lead on the bulb socket 
connector. 



4 



MEETS 
SPECIFICATION 



This circuit is not faulty. 



OUT OF SPECIFICATION 



1 



The wiring circuit from the turn switch to the 
bulb socket connector is faulty, repair it. 



8-44 



SIGNAL SYSTEM 



4. If the neutral indicator light fails to come on: 



1 . Bulb and bulb socket 



Check the bulb and bulb socket for continu- 
ity. 



ft 



CONTINUITY 



2. Neutral switch 



Disconnect the neutral switch lead from the 
neutral switch. 

Check for continuity as follows: 
Neutral switch terminal ©-Ground 





ft 



CONTINUITY 



3. Diode 



• Remove the diode from the wire harness. 

• Check for continuity as follows: 
Sky blue® - Light green© 




X 


Lg 


Sb 



Tester (+) lead 
Tester (-) lead 



Sky blue ® 
Light green (2) 



Tester (+) lead 
Tester (-) lead 



Light green (T) 
Sky blue© 



Continuity 



No 
Continuity 



ft 



CORRECT 



* 



ELEC 


+ 



NO CONTINUITY 



I 



Replace the bulb and/or bulb socket. 



NO CONTINUITY 



1 



Replace the neutral switch. 



INCORRECT 



l 



Replace the diode. 



8-45 



SIGNAL SYSTEM 



* 



4 



4. Voltage 



Connect the pocket tester (DC 20 V) to the 
bulb socket coupler. 



Tester (+) lead — ► Brown terminal ® 
Tester (-) lead -+ Frame ground 



Turn the main switch to "ON". 
Check the voltage (12 V). 



4 



MEETS 
SPECIFICATION 



This circuit is not faulty. 



ELEC 




+ 






OUT OF SPECIFICATION 



I 



The wiring circuit from the main switch to the 
bulb socket connector is faulty, repair it. 



5. If the oil level warning light fails to come on: 



1 . Bulb and bulb socket 



Check the bulb and bulb socket for continu- 
ity. 



4 



CONTINUITY 



2. Starting circuit cut-off relay 



• Disconnect the starting circuit cut-off relay 
coupler from the wire harness. 

• Connect the pocket tester (£1 x 1 00) to the 
starting circuit cut-off relay coupler termi- 
nals. 

• Check the resistor for the specified resis- 
tance. 



Tester (+) terminal -► 

Black/Red terminal® 
Tester (-) terminal -+ White/Black® 



m 



8 a at 20°C 



4 



MEETS 
SPECIFICATION 



* 



NO CONTINUITY 



1 



Replace the bulb and/or bulb socket. 



^D 



Nfc 



^S^ 



i 



R R/B L/W G/W B/R 



V G/WB/R] 

I B/Y B W/ffl 



L/B L/Y Lg B/Y B W/B 



OUT OF SPECIFICATION 



I 



Replace the starting circuit cut-off relay. 



8-46 



SIGNAL SYSTEM 



3. Oil level switch 



• Drain the engine oil and remove the oil level 
switch from the oil pan. 

• Connect the pocket tester (£2 x 1) to the oil 
level switch. 



Tester (+) lead -► Black/ Red terminal ® 
Tester (-) lead -► Frame ground 



Check the oil level switch for continuity. 



4 



CONTINUITY 



4. Diode (starting circuit cut-off relay) 



• Remove the relay unit from the wire har- 
ness. 

• Check for continuity as follows: 
White/Black®- Black© 



XD 













,' 


^~ 






X 




-J? 



i 



RR/BL/W G/WB/R 



V G/WB/Rj 

i b/y b w/b] 



L/B L/YLg B/Y B W/B 



Tester (+) lead 
Tester (-) lead 



White/Black® 
Black (2) 



Tester (+) lead 
Tester (-) lead 



Black ® 
White/ Black (2) 



Continuity 



No 
Continuity 



4 



CORRECT 



* 



ELEC 


+ 





NO CONTINUITY 



1 



Replace the oil level switch. 



INCORRECT 



I 



Replace the relay unit. 



8-47 



SIGNAL SYSTEM 



5. Start switch 



Disconnect the right handlebar switch cou- 
pler from the wire harness. 
Check for continuity as follows: 
Blue/White®- Black© 




OFF 



ON 



L/W 



QzO 



©Ug/y 



L/W 



R/W 



R/W 



I 



Br 



4 



CONTINUITY 



6. Voltage 



Connect the pocket tester (DC 20 V) to the 
bulb socket connector. 



Tester (+) lead -► Brown lead ® 
Tester (-) lead -+ Black/ Red lead (2) 



Turn the main switch to "ON" 
Check the voltage (12 V). 



4 



MEETS 
SPECIFICATION 



This circuit is not faulty. 



ELEC 




+ 





NO CONTINUITY 



1 



Replace the right handlebar switch. 





? 






G 


R/G 


W 










/ 
Br 


L 


B l 




Ch 


Sb 


Y 


B/R 


Y/B 




Dg G/WG/R 


G 




& 





OUT OF SPECIFICATION 



1 



The wiring circuit from the main switch to the 
bulb socket connector is faulty, repair it. 



8-48 



SIGNAL SYSTEM 



ELEC 


+ 



6. If the fuel level warning light fails to come on 
or the fuel meter fails to operate: 



1 . Bulb and bulb socket 



Check the bulb and bulb socket for continu- 
ity. 



a 



CONTINUITY 



2. Fuel sender 



• Drain the fuel and remove the fuel sender 
from the fuel tank. 

• Disconnect the fuel sender coupler from the 
wire harness. 

• Connect the pocket tester (CI x 1) to the 
fuel sender. 



Tester (+) lead -► Green/Red terminal ® 
Tester (-) lead -► Black terminal (3) 



• Check the fuel sender for continuity. 

• Connect the pocket tester (CI x 1) to the 
fuel sender. 



Tester (+) lead 
Tester (-) lead 



Green terminal (2) 
Black terminal (3) 



• Measure the fuel sender resistance. 



m 



Fuel sender resistance 
(4): 4 ~ 10Oat20°C 
(5): 90 ~ 100Oat20°C 



4 



MEETS 
SPECIFICATION 



3. Fuel meter 



• Drain the fuel and remove the fuel sender 
from the fuel tank. 

• Connect the fuel sender to wireharness. 

• Move the float to "UP"© or "DOWN"©. 



© 




• Turn the main switch to "ON". 

• Check the fuel gauge needle moves "F" or 
"E". 



Float position 



Float "UP" © 



Float "DOWN" (2) 



Needle moves 



NO CONTINUITY 



I 



Replace the bulb and/or bulb socket. 




OUT OF SPECIFICATION 



I 



Replace the fuel sender. 



NOTE: 

Before reading the meter, stay put the float for 
more than three minutes respectively at "UP" or 
"DOWN". 



DOES NOT MOVE 



1 



Replace the fuel meter. 



8-49 



SIGNAL SYSTEM 



ELEC 




+ 





3. Voltage 



• Connect the pocket tester (DC 20 V) to the 
bulb socket connector. 



Tester (+) lead 
Tester (-) lead 



Brown terminal ® 
Green/Red terminal (2) 





? 






G 


R/G 


W 










Br 


L 


B] 




Ch 


Sb 


Y 


B/R 


Y/B 




Dg G/WG>(R 


G 




h 





Drain the fuel. 

Turn the main switch to "ON". 

Check the voltage (12 V). 



OUT OF SPECIFICATION 



1 



$■ 



MEETS 
SPECIFICATION 



The wiring circuit from the main switch to the 
bulb socket connector is faulty, repair it. 



This circuit is not faulty. 



8-50 



COOLING SYSTEM 



ELEC 


+ 



COOLING SYSTEM 

CIRCUIT DIAGRAM 



r*""r* r**~r* |ffljl 



.,_, 




_c 




D) 




D) 




C 




C 




s— 




03 




£ 




CD 


c 


=3 


03 




H — 


03 


' ' 


CD 
Q. 

E ^ 


o ^ 


O 


W C o) 


^ 


o 3 "c/> 


E ^~^ ^~^ 




5-0 


D) C 


(/) (/) 


C 03 


-C 3 3 


LU LL 


1— LL LL 


©® 


S>@© 




-C^ 




O "•""' 




^ +^-c 


o 


c ^.^ 


-1—' 


03 CO 


n sw 

ery 

e (m 

rmo 
rninc 


13 


CO 03 


©©©® 




8-51 



COOLING SYSTEM 



ELEC 




+ 





EB807010 

TROUBLESHOOTING 



IF THE FAN MOTOR FAILS TO TURN: 

IF THE WATER TEMPERTATURE METER FAILS TO MOVE, WHEN THE ENGINE IS WARM: 



Procedure 

Check: 

1 . Fuses (main, signal and fan) 

2. Battery 

3. Main switch 

4. Fan motor 

5. Thermo switch 



6. Engine temperature warning light 

7. Voltage 

8. Wiring connections (the entire cooling 
system) 



NOTE: 

• Remove the following part(s) before trouble- 
shooting. 

1) Seat 

2) Fuel tank 

3) Front cowling assembly 

• Use the following special tool(s) for trouble- 
shooting. 




Pocket tester: 
90890-03112 



1 . Fuses (main, signal and fan) 



• Remove the fuses. 

• Connect the pocket tester (£1 x 1) to the 
fuses. 

• Check the fuses for continuity. 



4 



CONTINUITY 



2. Battery 



Check the battery condition. 

Refer to "BATTERY INSPECTION" in 

CHAPTER 3. 



Open-circuit voltage: 
12.8 V or more at 20 °C 



4 



CORRECT 



* 



NO CONTINUITY 



I 



Replace the fuse(s). 



INCORRECT 



1 



Clean the batery terminals. 
Recharge or replace the battery. 



8-52 



COOLING SYSTEM 



* 



4 



3. Main switch 



Disconnect the main switch coupler from 

the wire harness. 

Check for continuity as follows: 

Red ® - Brown/Blue (2) 




Br/L 



ON 



OFF 



% 



oo 



w 



L/R L 



OO 



IVY 



OO 



Br/L 



S 



ft 



CONTINUITY 



4. Fan motor 



• Disconnect the fan motor coupler. 

• Connect the battery (12 V) as shown. 



Battery (+) lead -► Black terminal ® 
Battery (-) led -+ Black terminal (2) 




n 


^ 




D 




. i i 


B 

y4 




+J L^ 
12V 



Check the operation of the fan motor. 



a 



MOVES 



* 



ELEC 


+ 



NO CONTINUITY 



1 



Replace the main switch. 



DOES NOT MOVE 



I 



The fan motor is faulty, replace it. 



8-53 



COOLING SYSTEM 



ELEC 




+ 





* 



4 



5. Thermo switch (fan, engine temperature) 


• Remove the thermo switch from the thermo- 
static valve housing. 

• Connect the pocket tester (£2 x 1) to the 
thermo switch ©. 

• Immerse the thermo switch in coolant (2). 

• Check the thermo switch for continuity. 
While heating the coolant use a thermome- 
ter (3) to record the temperatures. 


Test 
step 


Water temperature 


Good 
condition 


Thermo switch 


1 


~ 105°C 


X 


2 


More than 105C 


O 


3* 


105to98°C 


O 


4* 


Lesthan98°C 


X 


Tests 1 & 2; Heat-up tests 

Tests 3* & 4*; Cool-down tests 

O: Continuity x : No continuity 



9 8°C ffl 



105°C 



\E THERMO SWITCH "ON" 
E THERMO SWITCH "OFF" 



4 



GOOD 
CONDITION 



A WARNING 



Handle the thermo switch with special care. 
Never subjct it to strong shocks or allow it to 
be dropped. Should it be dropped, it must be 
replaced. 




BAD CONDITION 



\ 



Replace the thermo switch. 



* 



8-54 



COOLING SYSTEM 



* 



& 



6. Engine temperature warning light 



Check the bulb and bulb socket for continu- 
ity. 



4 



CONTINUITY 



7. Voltage 



• Connect the pocket tester (DC 20 V) to the 
bulb socket connector. 



Tester (+) lead -► Brown lead ® 
Tester (-) lead -► Green/White lead (2) 



Turn the main switch to "ON". 
Check the voltage (12 V). 



a 



MEETS 
SPECIFICATION 



8. Wiring connections 



Check the connections of the entire cooling 

system. 

Refer to "CIRCUIT DIAGRAM. 



A 



CORRECT 



This circuit is not faulty. 



ELEC 


+ 



NO CONTINUITY 



1 



Replace the bulb and/or bulb socket. 





? 






G 


R/G 


W 










Br 


L 


B l 




Ch 


Sb 


Y 


B/R 


Y/B 




Dg G/WG/R 


G 




6 





OUT OF SPECIFICATION 



a 



The wiring circuit from the main switch to the 
bulb socket connector is faulty, repair it. 



POOR CONNECTION 



\ 



Properly connect the cooling system. 



8-55 



FUEL PUMP SYSTEM 



ELEC 




+ 





FUEL PUMP SYSTEM 

CIRCUIT DIAGRAM 



r*"r# r^r* |Hl 











_c 












o 










>^ 


-t— » 










CC 


£ 


^_^ 








CD 


CO 


c 


-C 






L. 


Q. 


o 


o 






Q_±± 


Q- O 


■•— ' 


-1—' 
CO 


CD 


ctf 
0) 


1 pum 
tor un 


1 pum 
ine st 


0) 




J_! 


CO 


CD ~ 


CD D) 


CO 


CT5 


ctf 


~5 


=5 ™ 


13 C 


~5 


^ 


CD 


LL 


|_L ^ 


LL LU 


LL 


©@©(§)@)©®® 



© 


hx.Vccii y 


%n 




i 


? !E 




i 


5 1 

— < 

± 2 




8-56 



FUEL PUMP SYSTEM 



ELEC 


+ 



EB808010 

FUEL PUMP CIRCUIT OPERATION 

The fuel pump circuit consists of the fuel pump 

relay, fuel pump, engine stop switch and ignitor 

unit. 

The ignitor unit includes the control unit for the 

fuel pump. 



® Battery 

(2) Fuse (main) 

(3) Main switch 

(4) Fuse (ignition) 

(5) Engine stop switch 

(6) Ignitor unit 

(7) Fuel pump relay 

(8) Fuel pump 




8-57 



COOLING SYSTEM 



ELEC 




+ 





EB808020 

TROUBLESHOOTING 



IF THE FUEL PUMP FAILS TO OPERATE: 



Procedure 

Check: 

1 . Fuses (main and ignition) 

2. Battery 

3. Main switch 

4. Engine stop switch 



5. Fuel pump relay (starting circuit cut-off relay) 

6. Fuel pump resistance 

7. Wiring connections (the entire fuel system) 



NOTE: 

• Remove the following part(s) before trouble- 
shooting: 

1) Seat 

2) Fuel tank 

3) Side cover (left) 

• Use the following special tool(s) for trouble- 
shooting. 




Pocket tester: 
90890-03112 



1 . Fuses (main and ignition) 



• Remove the fuses. 

• Connect the pocket tester {£1 x 1) to the 
fuses. 

• Check the fuses for continuity. 



4 



CONTINUITY 



2. Battery 



Check the battery condition. 

Refer to "BATTERY INSPECTION" in 

CHAPTER 3. 



Open-circuit voltage: 
12.8 V or more at 20 °C 



4 



CORRECT 



* 



NO CONTINUITY 



1 



Replace the fuse(s). 



INCORRECT 



1 



Clean the battery terminals. 
Recharge or replace the battery. 



8-58 



FUEL PUMP SYSTEM 



ELEC 


+ 



* 



4 



3. Main switch 



Disconnect the main switch coupler from 

the wire harness. 

Check for continuity as follows: 

Red ® - Brown/Blue (2) 




Br/L 



ON 



OFF 



% 



o-o 



EE 



L/R L 



OO 



IVY 



OO 



Br/L 



T 



ft 



CONTINUITY 



4. Engine stop switch 



Disconnect the right handlebar switch cou- 
pler from the wire harness. 
Check for continuity as follows: 
Red/White ® - Red/White (2) 




OFF 



ON 



R/W 



Q- 



R/W 



O 



G/Y 



L/W 



j^ 



Ei 5 



R/W 



R/W 



Br 



4 



CONTINUITY 



5. Fuel pump relay (starting circuit cut-off 
relay) 



• Remove the relay unit from the wire har- 
ness. 

• Connect the pocket tester (£1 x 1 ) and bat- 
tery (12 V) to the relay unit terminals. 



NO CONTINUITY 



\ 



Replace the main switch. 



NO CONTINUITY 



1 



Replace the right handlebar switch. 



t 



2^1 \-jy~ 



<cr* 



R/BL/W G/WB/R 



L/B L/Y Lg B/Y B W/B| 



j/bJ 



8-59 



FUEL PUMP SYSTEM 



Battery (+) terminal -► 

Red/Black terminal® 
Battery (-) terminal -► 

Blue/Red terminal® 



Tester (+) lead -► Red/Black terminal ® 
Tester (-) lead -► Blue/ Black terminal (3) 



Check the fuel pump relay for continuity. 



& 



CONTINUITY 



6. Fuel pump resistance 



• Disconnect the fuel pump coupler from the 
wire harness. 

• Connect the pocket tester (£1 x 1) to the 
fuel pump coupler terminals. 



Tester (+) lead -► Black/Blue terminal ® 
Tester (-) lead -+ Black terminal (2) 



Check if the fuel pump has the specified re- 
sistance. 



a. 



Fuel pump resistance: 
1.8 ~ 2.6ftat20°C 



4 



MEETS 
SPECIFICATION 



7. Wiring connections 



• Check the connections of the entire fuel 
pump system. 
Refer to "CIRCUIT DIAGRAM". 



4 



CORRECT 



Replace the ignitor unit. 



ELEC 


+ 



NO CONTINUITY 



1 



Replace the starting circuit cut-off relay. 




OUT OF SPECIFICATION 



1 



Replace the fuel pump. 



POOR CONNECTION 



1 



Properly connect the fuel pump system. 



8-60 



FUEL PUMP SYSTEM 



EB808030 

FUEL PUMP TEST 



ELEC 


+ 



A WARNING 




Gasoline is extremely flammable and un- 
der certain circumstances there can be 
danger of an explosion or combustion. 
Be extremely careful and note the follow- 
ing points: 

• Stop the engine before refuelling. 

• Do not smoke and keep away from open 
flames, sparks, or any other source of 
fire. 

• Take care not to spill gasoline. If you do 
accidentally spill some, wipe it up im- 
mediately with dry rags. 

• If gasoline touches the engine when the 
engine is still hot, there is a danger of 
combustion. Make sure that the engine 
is completely cool before performing 
the following test. 

1. Check: 

• Fuel pump operation 

a. Fill up the fuel tank. 

b. Put the end of the fuel hose into an open 
container. 

c. Connect the battery (12 V) to the fuel 
pump coupler terminals. 



Battery (+) lead 
Battery (-) lead 



Black terminal (T) 
Black terminal (2) 



d. If fuel flows out from the fuel hose, the fuel 
pump is good. If not, replace the fuel 
pump assembly. 



8-61 



SELF-DIAGNOSIS 



ELEC 




+ 





SELF-DIAGNOSIS 

The YZF600R features self-diagnosis. 

When the main switch is turned to "ON", the following items are monitored and the condition codes are 

displayed on the tachometer (irrespective of whether the engine is running or not). 



Item 


Condition 


Response 


Display condition 
code 


Throttle position 
sensor (TPS) 


Disconnected 

Short-circuit 

Locked 


• Enables the motorcycle to run 
so that the ignition timing is fixed 
when the throttle is fully opened. 

• Displays the condition code on 
the tachometer. 


3,000 r/min 


Speed sensor 


Disconnected 
short-circuit 
Wheel IC fails 
to pulse 


• Displays the condition code on 
the tachometer. 


4,000 r/min 



Display order on the tachometer 

1 . Fail to the throttle position sensor 



(Xl000f/min) 












10" 














c 














o 














C/) 












Tachometer display 


> 












A Engine speed 


i 


i 5 - 












/ 












I "" 


- -^ 




/ 




1 


L*-^1 


1- 




I I 


I I 


I I I 


i i i 


i i 


i i 


di 


i i i i i 


..,.J 




















^ ® r/min. ..3 seconds 




.©, 


.©. 


,®. 


.©. 


.©. 


■ ®. 


■ ®. 


.©. 


.®. 


(2) Display condition 
















code. ..2.5 seconds 






■" Second 






[g) tngine speed. ..3 seconas 



While the engine is stopped, the engine speed ® is shown as r/min. 
2. Fail to speed sensor 



(XlOOOr/min) 



o 
"co 

o 
> 

CD 

DC 



Tachometer display 

Engine speed 



l I 



®. 



_L_L 



i I I 



I I I 



© 



J L 



J L 




■► Second 



® r/min. ..3 seconds 
(§) Display condition 

code. ..2.5 seconds 
(3) Engine speed. ..3 seconds 



While the engine is stopped, the engine speed ® is shown as r/min. 

8-62 



SELF-DIAGNOSIS 



ELEC 


+ 



TROUBLESHOOTING 



The tachometer starts to display the self-diagnosis sequence. 



NOTE: 

Use the following special tool in this trouble- 
shooting. 



y- 



Pocket tester: 
90890-03112 



1. Throttle position sensor (TPS) 

CIRCUIT DIAGRAM 



I WLk^k 



MAIN HARNESS 



fH 



kbU.ls.hUMcH 



COAD HEADLIGHT 



ESS SUB LEAD 



®, 



mmm 



\s\ ® 



© 



!® 



x© 



rar 






© 



- 9 <&s b -Qr 



(Q) Ignitor unit 

© Throttle position sensor (TPS) 



LWire harness 



Check the wire harness for continuity. 
Refer to "CIRCUIT DIAGRAM". 



NO CONTINUITY 



i 



jj. 



CONTINUITY 



Repair or replace the wire harness. 



2. TPS 



• Check the TPS for continuity. 

• Refer to "THROTTLE POSITION SENSOR 
(TPS) ADJUSTMENT AND INSPECTION" 
in CHAPTER 6. 



BAD CONDITION 



1 



Replace the TPS. 



4 



GOOD 
CONDITION. 



Replace the ignitor unit. 



8-63 



SELF-DIAGNOSIS 



2. Speed sensor 

CIRCUIT DIAGRAM 



ELEC 




+ 





iBi 



® 



® 



TTT 



_i®"" ; 



1© 



©)n 

®) ! 



./Y-@-L/Y- 



(8) 
)-Sb-^0-b— 

^3 



(JJ) Ignitor unit 
© Speed sensor 



LWire harness 



Check the wire harness for continuity. 
Refer to "CIRCUIT DIAGRAM". 



4 



CONTINUITY 



Replace the speed sensor. 



NO CONTINUITY 



1 



Repair or replace the wire harness. 



8-64 



CHAPTER 9. 
TROUBLESHOOTING 

STARTING FAILURE/HARD STARTING 9-1 

FUEL SYSTEM 9-1 

ELECTRICAL SYSTEM 9-1 

COMPRESSION SYSTEM 9-2 

POOR ENGINE IDLE SPEED PERFORMANCE 9-2 

POOR ENGINE IDLE SPEED PERFORMANCE 9-2 

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE 9-2 

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE 9-2 

FAULTY GEAR SHIFTING 9-3 

HARD SHIFTING 9-3 

SHIFT PEDAL DOES NOT MOVE 9-3 

JUMPS-OUT-OF GEAR 9-3 

FAULTY CLUTCH PERFORMANCE 9-3 

CLUTCH SLIPPING 9-3 

CLUTCH DRAGGING 9-3 

OVERHEATING 9-4 

OVERHEATING 9-4 

OVERCOOLING 9-4 

OVERCOOLING 9-4 

POOR BRAKING 9-4 

POOR BRAKING EFFECT 9-4 

FAULTY FRONT FORK LEGS 9-4 

MALFUNCTION 9-4 

OIL LEAKAGE 9-4 

UNSTABLE HANDLING 9-5 

UNSTABLE HANDLING 9-5 

FAULTY LIGHTING AND SIGNAL SYSTEMS 9-5 

HEADLIGHT DOES NOT LIGHT 9-5 

BULB BURNT OUT 9-5 

FLASHER DOES NOT LIGHT 9-5 

FLASHER BLINKS SLOWLY 9-5 

FLASHER REMAINS LIT 9-5 

FLASHER BLINKS QUICKLY 9-5 

HORN DOES NOT SOUND 9-5 

FZS60098 WIRING DIAGRAM 



TRBL 
SHTG 


9 

• 



TRBL 
SHTG 


9 

• 



TRBL 
SHTG 


9 

• 



STARTING FAILURE/HARD STARTING 

EB900000 

TROUBLESHOOTING 

NOTE: 

The following guide for troubleshooting does not cover all the possible causes of problems. 

It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this 

manual for inspection, adjustment and replacement of parts. 



STARTING FAILURE/HARD STARTING 



FUEL SYSTEM 
Fuel tank 

• Empty 

• Clogged fuel filter 

• Clogged fuel strainer 

• Clogged fuel tank drain hose 

• Clogged roll-over valve 

• Clogged roll-over valve breather hose 

• Deteriorated or contaminated fuel 
Fuel cock 

• Clogged fuel hose 



Carburetor 

• Deteriorated or contaminated fuel 

• Clogged pilot jet 

• Clogged pilot air passage 

• Sucked-in air 

• Deformed float 

• Worn needle valve 

• Improperly sealed valve seat 

• Improperly adjusted fuel level 

• Improperly set pilot jet 

• Clogged starter jet 

• Faulty starter plunger 

• Improperly adjusted starter cable 
Air filter 

• Clogged air filter element 
Fuel pump 

• Faulty fuel pump 

• Faulty fuel pump relay 



ELECTRICAL SYSTEM 
Spark plug 

• Improper plug gap 

• Worn electrodes 

• Wire between terminals severed 

• Improper heat range 

• Faulty spark plug cap 
Ignition coil 

• Faulty spark plug lead 

• Broken body 
Full-transistor system 

• Faulty ignitor unit 

• Faulty pickup coil 



Switch and wiring 

• Faulty main switch 

• Faulty engine stop switch 

• Broken or shorted wiring 

• Faulty neutral switch 

• Faulty start switch 

• Faulty sidestand switch 

• Faulty clutch switch 
Starter motor 

• Faulty starter motor 

• Faulty starter relay 

• Faulty circuit cut-off relay 

• Faulty starter clutch 



9-1 



STARTING FAILURE/HARD STARTING/POOR ENGINE IDLE SPEED 
PERFORMANCE/POOR MEDIUM- AND HIGH-SPEED PERFORMANCE 



COMPRESSION SYSTEM 
Cylinder and cylinder head 

• Loose spark plug 

• Loose cylinder head or cylinder 

• Faulty cylinder head gasket 

• Worn, damaged or seized cylinder 

• Improperly sealed valve 

• Improper valve-to-valve seat contact 

• Improper valve timing 

• Faulty valve spring 



TRBL 
SHTG 


9 

• 



Piston and piston ring 

• Improperly installed piston ring 

• Worn, fatigued or broken piston ring 

• Seized piston ring 

• Seized or damaged piston 
Crankcase and crankshaft 

• Improperly seated crankcase 

• Seized crankshaft 



POOR ENGINE IDLE SPEED PERFORMANCE 



POOR ENGINE IDLE SPEED PERFORMANCE 
Carburetor 

• Improperly returned starter plunger 

• Loose pilot jet 

• Clogged pilot air jet 

• Improperly synchronized carburetors 

• Improperly adjusted idle speed 
(throttle stop screw) 

• Improper throttle cable free play 

• Flooded carburetor 



Electrical system 

• Faulty battery 

• Faulty spark plug 

• Faulty ignitor unit 

• Faulty pickup coil 

• Faulty ignition coil 
Valve train 

• Improperly adjusted valve clearance 
Air filter 

• Clogged air filter element 



POOR MEDIUM-AND HIGH-SPEED PERFORMANCE 

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE 

Refer to "STARTING FAILURE/HARD STARTING". (Fuel system, electrical system, compression 
system and valve train) 

Carburetor 

• Faulty diaphragm 

• Improperly adjusted fuel level 

• Clogged or loose main jet 
Air filter 

• Clogged air filter element 
Fuel pump 

• Faulty fuel pump 



9-2 



FAULTY GEAR SHIFTING/ 
FAULTY CLUTCH PERFORMANCE 



TRBL 
SHTG 


9 

• 



FAULTY GEAR SHIFTING 

HARD SHIFTING 

Refer to "CLUTCH DRAGGING". 

SHIFT PEDAL DOES NOT MOVE 
Shift shaft 

• Improperly adjusted shift pedal link 

• Bent shift shaft 
Shift cam, shift fork 

• Groove jammed with impurities 

• Seized shift fork 

• Bent shift fork guide bar 



Transmission 

• Seized transmission gear 

• Jammed impurities 

• Incorrectly assembled transmission 



JUMPS-OUT-OF GEAR 
Shift shaft 

• Improperly adjusted shift lever position 

• Improperly returned stopper lever 
Shift fork 

• Worn shift fork 



Shift cam 

• Improper thrust play 

• Worn shift cam groove 
Transmission 

• Worn gear dog 



FAULTY CLUTCH PERFORMANCE 

CLUTCH SLIPPING 
Clutch 

• Improperly adjusted clutch cable 

• Loose clutch spring 

• Fatigued clutch spring 

• Worn friction plate/clutch plate 

• Incorrectly assembled clutch 



Engine oil 

• Improper oil level 

• Improper viscosity (low) 

• Deterioration 



CLUTCH DRAGGING 
Clutch 

• Warped pressure plate 

• Unevenly tensioned clutch springs 

• Bent push rod 

• Broken clutch boss 

• Burnt primary driven gear bushing 

• Bent clutch plate 

• Swollen friction plate 

• Match marks not aligned 



Engine oil 

• Improper oil level 

• Improper viscosity (high) 

• Deterioration 



9-3 



OVERHEATING/OVERCOOLING/ 
POOR BRAKING/FAULTY FRONT FORK LEGS 



OVERHEATING 

OVERHEATING 
Ignition system 

• Improper spark plug gap 

• Improper spark plug heat range 

• Faulty ignitor unit 
Fuel system 

• Improper carburetor main jet setting 

• Improper fuel level 

• Clogged air filter element 
Cooling system 

• Faulty cooling fan 

• Faulty thermo stat 

• Faulty thermo switch 

• Improper coolant level (low) 

• Faulty radiator 

• Faulty radiator cap 

• Faulty water pump 



TRBL 
SHTG 


9 

• 



OVERCOOLING 

OVERCOOLING 

• Faulty cooling fan 



Compression system 

• Heavy carbon build-up 
Engine oil 

• Improper oil level 

• Improper oil viscosity 

• Inferior oil quality 
Brake 

• Brake drag 



Faulty thermo stat 
Faulty thermo switch 



POOR BRAKING 

POOR BRAKING EFFECT 
Disc brake 

• Worn brake pad 

• Worn disc 

• Air in brake fluid 

• Leaking brake fluid 

• Faulty cylinder cup kit 

• Faulty caliper seal kit 

• Loose union bolt 

• Broken brake hose 

• Oily or greasy brake disc/brake pad 

• Improper brake fluid level 



FAULTY FRONT FORK LEGS 



MALFUNCTION 

• Bent, deformed or damaged inner tube 

• Bent or deformed outer tube 

• Damaged fork spring 

• Worn or damaged slide metal 

• Bent or damaged damper rod 

• Improper oil viscosity 

• Improper oil level 



OIL LEAKAGE 

• Bent, damaged or rusty inner tube 

• Damaged or cracked outer tube 

• Damaged oil seal lip 

• Improperly installed oil seal 

• Improper oil level (too high) 

• Loose damper rod holding bolt 

• Broken cap bolt O-ring 

• Loose drain bolt 

• Damaged drain bolt gasket 



9-4 



UNSTABLE HANDLING/ 
FAULTY LIGHTING AND SIGNAL SYSTEMS 



TRBL 
SHTG 


9 

• 



UNSTABLE HANDLING 

UNSTABLE HANDLING 
Handlebar 

• Improperly installed or bent 
Steering 

• Improperly installed handlebar crown 

• Bent steering stem 

• Improperly installed steering shaft 
(improperly tightened ring nut) 

• Damaged ball bearing or bearing race 
Swingarm 

• Worn bearing or busing 

• Bent or damaged 
Rear shock absorber 

• Faulty spring 

• Oil and gas leakage 
Tire 

• Uneven tire pressures on both sides 

• Incorrect tire pressure 

• Uneven tire wear 



Front fork 

Uneven oil levels on both sides 

Uneven spring tension 

Broken spring 

Twisted front fork 
Wheel 

Incorrect wheel balance 

Deformed cast wheel 

Damaged bearing 

Bent or loose wheel axle 

Excessive wheel runout 
Frame 

Bent 

Damaged steering head tube 

Improperly installed bearing race 



FAULTY LIGHTING AND SIGNAL SYSTEMS 



HEADLIGHT DOES NOT LIGHT 

• Improper bulb 

• Too many electric accessories 

• Hard charging (broken stator coil wire, faulty 
rectifier/regulator) 

• Incorrect connection 

• Improperly grounded 

• Poor contacts (main or light switch) 
FLASHER DOES NOT LIGHT 

• Improperly grounded 

• Discharged battery 

• Faulty turn switch 

• Faulty flasher relay 

• Faulty wire harness 

• Loosely connected coupler 

• Burnt-out bulb 

• Faulty fuse 

FLASHER BLINKS SLOWLY 

• Faulty flasher relay 

• Faulty main and/or turn switch 

• Improper bulb 



BULB BURNT OUT 

Improper bulb 

Faulty battery 

Faulty rectifier/regulator 

Improperly grounded 

Faulty main and/or light switch 

Bulb life expired 
FLASHER REMAINS LIT 

Faulty flasher relay 

Burnt-out bulb 
FLASHER BLINKS QUICKLY 

Improper bulb 

Faulty flasher relay 

Burnt-out bulb 
HORN DOES NOT SOUND 

Faulty battery 

Faulty fuse 

Faulty main and/or horn switch 

Improperly adjusted horn 

Faulty horn 

Broken wire harness 



9-5 



TRBL 
SHTG 


9 

• 



FZS600 98 WIRING DIAGRAM 




COLOR CODE 




















B ... 


. Black 


P .. 


. . . Pink 


B/L.. 


Black/Blue 


G/W. 


. Green/White 


R/W 


. Red/White 


Br .. 


. Brown 


Lg. 




Light green 


B/R.. 


Black/ Red 


G/Y . 


. Green/Yellow 


R/Y. 


. Red /Yellow 


Ch . 


. Chocolate 


. 




Orange 


B/W . 


Black/ 


L/B.. 


. Blue/Black 


W/B 


. White/Black 


Dq . 


. Dark green 


R.. 




Red 


B/Y.. 


Black/Yellow 


L/R.. 


. Blue/Red 


W/G 


. White/Green 


G .. 


. Green 


Sb. 




Sky blue 


Br/L . 


Brown/Blue 


L/W . 


. Blue/White 


W/R 


. White/ Red 


Gy . 


. Gray 


W . 




White 


Br/W 


Brown /White 


L/Y.. 


. Blue/Yellow 


Y/B. 


. Yellow/ Black 


L ... 


. Blue 


Y .. 




Yellow 


G/R . 


Green/ Red 


R/B.. 


. Red/Black 


Y/R. 


. Yellow/ Red 



® A.C. magneto 

(2) Rectifier/regulator 

(3) Main switch 
Battery 

(5) Fuse (back up) 

(6) Fuse (main) 

(7) Starter relay 

(8) Starter motor 

(9) Starting circuit cut-off relay 
© Fuel pump relay 

(0) Ignitor unit 

© Ignition coil 

© Spark plug 

© Pick up coil 

© Throttle position sensor 

© Neutral switch 

© speed sensor 

@ Fuel sender 

© Thermo switch (engine temperature) 

© Diode 

© Fuel pump 

© Sidestand switch 

© Speedometer 

© Tachometer 

© Fuel meter 

@ Fuel level warning light 

© Engine temperature warning light 

@ Neutral indicator light 

© Oil level warning light 

© High beam indicator light 

©Turn indicator light 

© Meter light 

© Clutch switch 

©Oil level switch 

© Flasher relay 

©Horn 

© Pass switch 

© Dimmer switch 

© Horn switch 

@ Turn switch 

@ Front turn signal light 

© Rear turn signal light 

© Headlight 

©Tail/Brake light 

© Auxiliary light 

@ Fan motor 

@ Thermo switch (fan motor) 

© Fuse (fan) 

© Fuse (head) 

© Rear brake switch 

© Fuse (signal) 

© Front brake switch 

© Light switch 

© Engine stop switch 

© Starter switch 

@ Fuse (ignition) 

@ Alarm (option)